Chevrolet - Impala - Workshop Manual - 2000 - 2000

Factory Workshop Manual Make Chevrolet Model Impala Engine and year V6-3.4L VIN E (2000) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Located in the LH instrument panel fuse block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > BCM - Related Service, Theft Deterrent Relearn Procedure Alarm Module: Technical Service Bulletins BCM - Related Service, Theft Deterrent Relearn Procedure File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-057A Date: May, 2000 INFORMATION Subject: Body Control Module (BCM) Related Service, Theft Deterrent Re-Learn Procedure Models: 2000 Chevrolet Impala, Monte Carlo This bulletin is being revised to update the service procedure and the labor time information. Please discard Corporate Bulletin Number 99-06-O4-057 (Section 6 - Engine/Propulsion System). BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: - The vehicle will not be protected against theft by the Passlock(TM) system. - The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 12 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (*) You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 13 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. 47. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 48. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 49. Select Set Options and press Enter. 50. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 51. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 52. Select Set Option Configuration and press Enter. 53. Press the key under the highlighted Done area of the Tech 2 display. 54. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 55. Exit back to the Main Menu screen. 56. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 57. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 58. Turn the ignition switch to OFF and wait 15 seconds. 59. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 60. The Security and Battery messages will begin toggling. 61. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 62. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 63. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 64. The Security and Battery messages will begin toggling. 65. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 66. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 67. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 14 release the ignition switch to the RUN position (the engine will not crank). 68. The Security and Battery messages will begin toggling. 69. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 70. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 71. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N4800 Computer (Control), Body - 1.1 hrs Replace and Program Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 15 Alarm Module: Service and Repair Programming Replacement Lock Cylinder, BCM or PCM IMPORTANT: Reprogram the body control module (BCM) with the proper RPO configurations before you perform the learn procedures. When you replace the BCM, the module will learn PASSLOCK Sensor Data Code immediately. However, the existing PCM must learn the new fuel continue password. When you replace a PCM, after programming, these modules will learn the incoming fuel continue password immediately upon receipt of a password message. Once a password message is received, and a password is learned, perform the learn procedure again if you want to change this password. A PCM which was previously installed in another vehicle will have learned the other vehicle's fuel continue password, and will require a learn procedure after programming in order to learn the current vehicle's password. Always use GM Service Parts Operations (SPO) Replacement Parts. 10 Minute Re-Learn Procedure Use this procedure after replacing any of the following components: 1. Lock Cylinders/PASSLOCK Sensors 2. BCM 3. PCM Tech 2 Programming Procedure Use the following procedures in order to program the BCM with the Tech 2 equipment. 1. Connect the Tech 2 Diagnostic tool. 2. Select Request Information under Service Programming. 3. Disconnect the Tech 2 from the vehicle and connect it to a Techline Terminal. 4. On the Techline Terminal, select Theft Module Re-Learn under Service Programming. 5. Disconnect the Tech 2 from the Techline Terminal and connect the Tech 2 to the vehicle. 6. Turn ON the ignition, with the engine OFF. 7. Select VTD Re-Learn under Service Programming. 8. At this point you may disconnect the Tech 2, the Tech 2 is no longer required. 9. Observe the Security telltale, after approximately 10 minutes the telltale will turn OFF. The vehicle is now ready to relearn the PASSLOCK Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. 10. Turn OFF the ignition, and wait 5 seconds. 11. Start the engine. (The vehicle has now learned keys). 12. Using a scan tool, clear any DTCs. 30 Minute Re-Learn Procedure Use this procedure after replacing lock cylinders, PASSLOCK Module/BCM or the PCM (if necessary - see note above). 1. Turn ON the ignition, with the engine OFF. 2. Attempt to start the engine, then release the key to ON (The vehicle will not start). 3. Observe the Security telltale, after approximately 10 minutes the telltale will turn OFF. 4. Turn OFF the ignition, and wait 5 seconds. 5. Repeat steps 1-4 two more times, for a total of 3 cycles and 30 minutes. The vehicle is now ready to relearn the PASSLOCK Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. IMPORTANT: The vehicle learns the PASSLOCK Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. You must turn the ignition OFF before attempting to start the vehicle. 6. Start the engine. (The vehicle has now learned the PASSLOCK Sensor Data Code and/or password.) 7. Using a scan tool, clear any DTCs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Service and Repair > Antenna Module Replacement Antenna Control Module: Service and Repair Antenna Module Replacement Antenna Module Replacement REMOVAL PROCEDURE 1. Remove the LH rear quarter upper trim panel. 2. Disconnect the antenna amplifier electrical connector and the antenna coaxial cable. The antenna coaxial cable uses a sliding snap-lock. Pull the lock in order to remove the antenna coaxial cable. 3. Detach the black antenna leads from the glass. The upper lead is held to the body metal with a wiring clip. Carefully pry the clip out of the metal. 4. Remove the antenna amplifier bolt. 5. Remove the antenna amplifier. INSTALLATION PROCEDURE 1. Position the antenna amplifier to the LH rear window inner upper panel. Install the antenna amplifier bolt. Tighten Tighten the antenna amplifier bolt to 3 N.m (27 lb in). IMPORTANT: The antenna coaxial cable uses a sliding snap-lock. Holding the sliding lock feature will prevent installation. 2. Connect the antenna amplifier electrical connectors: 2.1. Position the antenna coaxial cable behind the sliding lock feature. 2.2. Install the antenna coaxial cable to the sliding lock feature. IMPORTANT: If the wiring clip is faulty, the wiring clip must be replaced prior to installation. 3. Install the antenna leads to the rear window terminals. Push the wiring clip on the upper lead into the hex hole in the metal. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Service and Repair > Antenna Module Replacement > Page 20 Antenna Control Module: Service and Repair Coaxial Cable Replacement REMOVAL PROCEDURE 1. Loosen the rear of the headliner in order to gain access. 2. Remove the antenna coaxial cable from the radio antenna module. 3. Remove the rear seat cushion. Refer to Seat Cushion Replacement - Rear in Seats. 4. Remove the rear seat back. 5. Remove the left carpet retainers. 6. Remove the lower center pillar trim panel. 7. Adjust the carpet for access to the wiring harness as required. 8. Remove the left instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Service and Repair > Antenna Module Replacement > Page 21 9. Adjust the radio for access. Disconnect the antenna coaxial cable from the rear of the radio. Refer to Radio Replacement. 10. Cut off the visible end of the coaxial antenna cable from the wiring harness in the kick panel area. 11. Cut off the visible end of the coaxial antenna cable from the wiring harness in the rear shelf area. INSTALLATION PROCEDURE 1. Install the coaxial antenna cables to the vehicle. Use electrical tape in order to secure the antenna extension cable to the top of the wiring harness. Make sure that the cable is secured to the harness at least every 150 mm (6 in). 2. Connect the coaxial antenna cable to the rear of the radio. Install the radio. IMPORTANT: The antenna coaxial cable uses a sliding snap-lock. Holding the sliding lock feature will prevent installation. 3. Connect the coaxial antenna cable from the radio to the coaxial antenna cable near the kick panel: 3.1. Position the antenna coaxial cable behind the sliding lock feature. 3.2. Install the antenna coaxial cable to the sliding lock feature. 4. Install the left instrument panel insulator. 5. Install the carpet. 6. Install the lower center pillar trim panel. 7. Install the left carpet retainers. 8. Connect the coaxial antenna cable from the body wiring harness to the coaxial antenna cable at the rear shelf area. 9. Install the rear seat back. 10. Install the rear seat cushion. IMPORTANT: The antenna coaxial cable uses a sliding snap-lock. Holding the sliding lock feature will prevent installation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Service and Repair > Antenna Module Replacement > Page 22 11. Connect the antenna coaxial cable to the radio antenna module. 11.1. Position the antenna coaxial cable behind the sliding lock feature. 11.2. Install the antenna coaxial cable to the sliding lock feature. 12. Install the rear of the headliner. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 31 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 32 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 33 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 34 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 35 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 36 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 37 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 38 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 39 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 40 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 41 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 42 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 43 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 44 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 45 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 46 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 47 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 48 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 49 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 50 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 51 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 52 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 53 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 54 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 55 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 56 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 57 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 58 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 59 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 60 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 61 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 62 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 63 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 64 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 70 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 75 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 81 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 86 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 87 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 88 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 89 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 90 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 91 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 92 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 93 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 94 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 95 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 96 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 97 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 98 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 99 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 100 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 101 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 102 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 103 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 104 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 105 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 106 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 107 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 108 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 109 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 110 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 111 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 112 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 113 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 114 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 115 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 116 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 117 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 118 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 119 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-64-007A > Sep > 08 > OnStar(R) - Analog Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 136 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-007 > Dec > 06 > OnStar - Analog-Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar - Analog-Only Systems Information Bulletin No.: 06-08-46-007 Date: December 13, 2006 INFORMATION Subject: Information on OnStar(R) Analog-Only Systems Models: 1996-2001 GM Passenger Cars and Trucks Plus: 2002 Buick LeSabre, Rendezvous 2002-2003 Buick Century, Regal 2002-2005 Buick Park Avenue 2002 Cadillac Eldorado, Escalade Models 2002 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Venture 2002 GMC Denali, Denali XL, Jimmy, Sierra, Yukon, Yukon XL 2002 Oldsmobile Intrigue, Silhouette 2002-2003 Oldsmobile Aurora 2002 Pontiac Aztek, Bonneville, Montana 2002-2003 Pontiac Grand Prix with OnStar(R) (RPO UE1) All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog/Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 146 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-64-007A > Sep > 08 > OnStar(R) - Analog Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 163 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-007 > Dec > 06 > OnStar - Analog-Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar - Analog-Only Systems Information Bulletin No.: 06-08-46-007 Date: December 13, 2006 INFORMATION Subject: Information on OnStar(R) Analog-Only Systems Models: 1996-2001 GM Passenger Cars and Trucks Plus: 2002 Buick LeSabre, Rendezvous 2002-2003 Buick Century, Regal 2002-2005 Buick Park Avenue 2002 Cadillac Eldorado, Escalade Models 2002 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Venture 2002 GMC Denali, Denali XL, Jimmy, Sierra, Yukon, Yukon XL 2002 Oldsmobile Intrigue, Silhouette 2002-2003 Oldsmobile Aurora 2002 Pontiac Aztek, Bonneville, Montana 2002-2003 Pontiac Grand Prix with OnStar(R) (RPO UE1) All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog/Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 173 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 174 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 175 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 176 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 177 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 178 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 179 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 180 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 181 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 182 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 183 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 184 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 185 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 186 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 187 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 188 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 189 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 190 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 191 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 192 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 193 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 194 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 195 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 196 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 197 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 198 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 199 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 200 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 201 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 202 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 203 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 204 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 205 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 206 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 231 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 232 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 233 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 239 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 240 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 241 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams Heated Seat Control Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Replacement Removal Procedure 1. Remove the front seat adjuster to floor pan bolts. 2. Tilt the seat forward. 3. Disconnect the electric connectors from the heated seat module. 4. Cut the tie straps to the module. 5. Remove the heated seat module. Installation Procedure 1. Position the heated seat module under the seat. 2. Connect the electric connectors to the heated seat module. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Page 249 3. Install new tie straps to the module. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the front bucket seat adjuster-to-floor pan bolts. Tighten the front bucket seat adjuster-to-floor pan bolts to 42 Nm (31 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Locations Seat Heater Relay: Locations Below the seat. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Module: > 02-08-67-001 > Feb > 02 > Headliner - Sags At Sunroof Opening Sunroof / Moonroof Module: Customer Interest Headliner - Sags At Sunroof Opening File In Section: 08 - Body and Accessories Bulletin No.: 02-08-67-001 Date: February, 2002 TECHNICAL Subject: Headliner Sags At Sunroof Opening (Reattach Velcro(R) Strips) Models: 2000-2001 Chevrolet Impala Condition Some customers may comment that the headliner sags at the front of the sunroof opening. Cause The Velcro(R) strips may have come loose from the sunroof module and/or the headliner. Correction Replace the Velcro(R) strips that may have pulled loose from the sunroof module and/or the headliner. Clean the surface of the sunroof module using one of the cleaners listed below. Make sure the two halves of the Velcro(R) strips are properly aligned with each other before reattaching them. Apply adhesion promoter, P/N 12378462 (in Canada, us 10953554), to the sunroof module to improve the 3M(R) Dual Lock(TM) strip retention. If the Velcro(R) strips have come loose from the headliner, use hot melt glue to reattach them. Parts Information Parts are currently available from GMSPO. To obtain 3M(R) Dual Lock(TM) Mini-Pack, purchase it locally. Cleaning Solvents ^ 3M(R) General Purpose Adhesive Cleaner, P/N 08984 ^ Dominion Sure Seal, Sure Solve Stock BSS ^ Kent Acrosol Warranty Information For vehicles repaired under warranty use the table as shown. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Module: > 02-08-67-001 > Feb > 02 > Headliner - Sags At Sunroof Opening > Page 261 DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Module: > 02-08-67-001 > Feb > 02 > Headliner - Sags At Sunroof Opening Sunroof / Moonroof Module: All Technical Service Bulletins Headliner - Sags At Sunroof Opening File In Section: 08 - Body and Accessories Bulletin No.: 02-08-67-001 Date: February, 2002 TECHNICAL Subject: Headliner Sags At Sunroof Opening (Reattach Velcro(R) Strips) Models: 2000-2001 Chevrolet Impala Condition Some customers may comment that the headliner sags at the front of the sunroof opening. Cause The Velcro(R) strips may have come loose from the sunroof module and/or the headliner. Correction Replace the Velcro(R) strips that may have pulled loose from the sunroof module and/or the headliner. Clean the surface of the sunroof module using one of the cleaners listed below. Make sure the two halves of the Velcro(R) strips are properly aligned with each other before reattaching them. Apply adhesion promoter, P/N 12378462 (in Canada, us 10953554), to the sunroof module to improve the 3M(R) Dual Lock(TM) strip retention. If the Velcro(R) strips have come loose from the headliner, use hot melt glue to reattach them. Parts Information Parts are currently available from GMSPO. To obtain 3M(R) Dual Lock(TM) Mini-Pack, purchase it locally. Cleaning Solvents ^ 3M(R) General Purpose Adhesive Cleaner, P/N 08984 ^ Dominion Sure Seal, Sure Solve Stock BSS ^ Kent Acrosol Warranty Information For vehicles repaired under warranty use the table as shown. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Module: > 02-08-67-001 > Feb > 02 > Headliner - Sags At Sunroof Opening > Page 267 DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Page 268 Sunroof / Moonroof Module: Specifications Sunroof Module Bolts 10 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Component Locations Sunroof / Moonroof Module: Component Locations Sunroof Module Locations View In the center of the roof, underneath the headliner. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Component Locations > Page 271 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Component Locations > Page 272 Sunroof / Moonroof Module: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Component Locations > Page 273 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions Sunroof / Moonroof Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 276 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 277 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 278 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 279 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 280 Sunroof / Moonroof Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 281 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 282 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 283 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 284 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 285 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 286 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 287 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 288 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 289 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 290 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 291 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 292 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 293 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 294 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 295 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 296 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 297 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 298 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 299 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 300 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 301 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 302 Sunroof / Moonroof Module: Connector Views Sunroof Module, C1 Sunroof Module, C2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 303 Sunroof / Moonroof Module: Electrical Diagrams Power Sunroof Schematics: Without Driver Information Center (DIC) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 304 Power Sunroof Schematics: With Driver Information Center (DIC) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Page 305 Sunroof / Moonroof Module: Service and Repair REMOVAL PROCEDURE 1. Position the sunroof to the fully closed position. 2. Remove the headliner. 3. Remove the express module from the sunroof module by sidling the express module towards the center of the vehicle. 4. Remove the express module from the vehicle. 5. Disconnect the electrical connectors from the express module. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Page 306 1. Position the express module to the sunroof module. 2. Connect the electrical connector to the express module. 3. Install the express module to the sunroof module by sliding the express module to the right, pressing into place until fully locked in position. 4. Check the sunroof for proper operation. 5. Install the headliner. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trunk / Liftgate Relay > Component Information > Locations > Rear Compartment Lid Lamp Relay Trunk / Liftgate Relay: Locations Rear Compartment Lid Lamp Relay Inside the top underhood accessory wiring junction block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON Electronic Brake Control Module: Customer Interest Tire Inflation Monitor - False Message/Lamp ON File In Section: 03 - Suspension Bulletin No.: 01-03-10-008A Date: February, 2002 TECHNICAL Subject: False Tire Inflation Monitor System (TIM) Message/Lamp Illumination (Install New Electronic Brake Traction Control Module - EBTCM) Models: 1999-2001 Buick Century, Regal This bulletin is being revised to add additional Existing ECU Part Numbers. Please discard Corporate Bulletin Number 01-03-1-008 (Section 03-Suspension) Condition Some owners may comment on the "Low Tire Pressure" message appearing or illumination of the "Low Tire" lamp. After checking the vehicle tire pressures, owners have indicated that none of the tires were found to be under inflated 12 psi (53 kPa) or more in comparison to the other three assemblies. This condition typically can be duplicated by operating the vehicle over a rough washboard type road surface. Correction Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON > Page 320 Replace the existing EBCM/EBTCM with a new component selected from the following table. To determine the correct part number to order, locate the ECU PN (1) as shown in figure, on the existing EBCM/EBTCM label. Then refer to the chart to determine the correct service part number. Follow the applicable SI 2000 service procedure indicated by vehicle year and model. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON Electronic Brake Control Module: All Technical Service Bulletins Tire Inflation Monitor - False Message/Lamp ON File In Section: 03 - Suspension Bulletin No.: 01-03-10-008A Date: February, 2002 TECHNICAL Subject: False Tire Inflation Monitor System (TIM) Message/Lamp Illumination (Install New Electronic Brake Traction Control Module - EBTCM) Models: 1999-2001 Buick Century, Regal This bulletin is being revised to add additional Existing ECU Part Numbers. Please discard Corporate Bulletin Number 01-03-1-008 (Section 03-Suspension) Condition Some owners may comment on the "Low Tire Pressure" message appearing or illumination of the "Low Tire" lamp. After checking the vehicle tire pressures, owners have indicated that none of the tires were found to be under inflated 12 psi (53 kPa) or more in comparison to the other three assemblies. This condition typically can be duplicated by operating the vehicle over a rough washboard type road surface. Correction Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON > Page 326 Replace the existing EBCM/EBTCM with a new component selected from the following table. To determine the correct part number to order, locate the ECU PN (1) as shown in figure, on the existing EBCM/EBTCM label. Then refer to the chart to determine the correct service part number. Follow the applicable SI 2000 service procedure indicated by vehicle year and model. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 00-05-23-006 > Sep > 00 > Rear Disc Brakes - Groan/Squeal Noises Brake Pad: All Technical Service Bulletins Rear Disc Brakes - Groan/Squeal Noises File In Section: 05 - Brakes Bulletin No.: 00-05-23-006 Date: September, 2000 Subject: Rear Disc Brake Groan/Squeal (Install New Rear Brake Pads) Models: 2000-2001 Chevrolet Impala, Monte Carlo Built Prior to VIN Breakpoint 19117621 Condition Some customers may comment on an audible groan/squeal type noise coming from the rear of the vehicle during a light brake apply. This condition is most likely to occur after the vehicle has sat overnight and may be apparent in either forward and/or reverse gears. Cause This noise may be generated at the rear brake pad/rotor interface during a brake application. The noise is then transmitted into the vehicle's underbody through the rear suspension components. Correction Replace the existing rear disc brake pads with those found in service kit, P/N 18023377, following the service procedure in the Disc Brake sub-section of the Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 337 Electronic Brake Control Module: Specifications Brake Pressure Modulator Valve (BPMV) and Electronic Brake Control Module (EBCM) Assembly to Mounting Bracket 89 in.lb Electronic Brake Control Module (EBCM) to Brake Pressure Modulator Valve (BPMV) 44 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Component Locations > Page 340 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Electronic Brake Traction Control Module (EBTCM), C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Electronic Brake Traction Control Module (EBTCM), C1 > Page 343 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 344 Electronic Brake Control Module: Service and Repair Removal Procedure Notice: To prevent equipment damage, never connect or disconnect the wiring harness connection from the EBCM with the ignition switch in the ON position. 1. Turn the ignition switch to the OFF position. 2. Remove red locking tab from connector lock tab (1). 3. Push down lock tab (1) and then move sliding connector cover (2) to the open position. 4. Disconnect the EBCM harness connector. 5. Brush off any dirt/debris that has accumulated on the assembly. 6. Remove the four EBCM to BPMV screws (1). 7. Separate the EBCM (2) from the BPMV (3) by gently pulling apart until separated. Important: Do not pry apart using a tool. Be careful not to damage BPMV surface. Important: Care must be taken not to damage the solenoid valves when the EBCM is removed from the BPMV. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 345 1. Clean the BPMV surface with alcohol using a clean rag. 2. Install the EBCM (2) to the BPMV (3). 3. Install the four screws (1) that attaches the EBCM (2) to BPMV (3). Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the four screws to 5 Nm (44 inch lbs.). 4. Connect the EBCM harness connector. 5. Push down lock tab (1) and then move sliding connector cover (2) back in the home position to lock. 6. Insert red locking tab back in place. 7. Turn the ignition switch to the RUN position, do not start engine. 8. Perform the A Diagnostic System Check - ABS. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON Traction Control Module: Customer Interest Tire Inflation Monitor - False Message/Lamp ON File In Section: 03 - Suspension Bulletin No.: 01-03-10-008A Date: February, 2002 TECHNICAL Subject: False Tire Inflation Monitor System (TIM) Message/Lamp Illumination (Install New Electronic Brake Traction Control Module - EBTCM) Models: 1999-2001 Buick Century, Regal This bulletin is being revised to add additional Existing ECU Part Numbers. Please discard Corporate Bulletin Number 01-03-1-008 (Section 03-Suspension) Condition Some owners may comment on the "Low Tire Pressure" message appearing or illumination of the "Low Tire" lamp. After checking the vehicle tire pressures, owners have indicated that none of the tires were found to be under inflated 12 psi (53 kPa) or more in comparison to the other three assemblies. This condition typically can be duplicated by operating the vehicle over a rough washboard type road surface. Correction Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON > Page 354 Replace the existing EBCM/EBTCM with a new component selected from the following table. To determine the correct part number to order, locate the ECU PN (1) as shown in figure, on the existing EBCM/EBTCM label. Then refer to the chart to determine the correct service part number. Follow the applicable SI 2000 service procedure indicated by vehicle year and model. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON Traction Control Module: All Technical Service Bulletins Tire Inflation Monitor - False Message/Lamp ON File In Section: 03 - Suspension Bulletin No.: 01-03-10-008A Date: February, 2002 TECHNICAL Subject: False Tire Inflation Monitor System (TIM) Message/Lamp Illumination (Install New Electronic Brake Traction Control Module - EBTCM) Models: 1999-2001 Buick Century, Regal This bulletin is being revised to add additional Existing ECU Part Numbers. Please discard Corporate Bulletin Number 01-03-1-008 (Section 03-Suspension) Condition Some owners may comment on the "Low Tire Pressure" message appearing or illumination of the "Low Tire" lamp. After checking the vehicle tire pressures, owners have indicated that none of the tires were found to be under inflated 12 psi (53 kPa) or more in comparison to the other three assemblies. This condition typically can be duplicated by operating the vehicle over a rough washboard type road surface. Correction Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON > Page 360 Replace the existing EBCM/EBTCM with a new component selected from the following table. To determine the correct part number to order, locate the ECU PN (1) as shown in figure, on the existing EBCM/EBTCM label. Then refer to the chart to determine the correct service part number. Follow the applicable SI 2000 service procedure indicated by vehicle year and model. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Pressure Control Solenoid Replacement File In Section: 07 - Transmission/Transaxle Bulletin No.: 02-07-30-048 Date: November, 2002 INFORMATION Subject: Pressure Control Solenoid Replacement for 4T65-E, 4T40-E, and 4T45-E Transaxle/Transmission Models: 2000-2003 Buick Century, LeSabre, Park Avenue, Regal 2002-2003 Buick Rendezvous 2000-2001 Chevrolet Lumina 2000-2003 Chevrolet Cavalier, Impala, Malibu, Monte Carlo, Venture 2000-2002 Oldsmobile Intrigue 2000-2003 Oldsmobile Alero, Silhouette 2000-2003 Pontiac Bonneville, Grand Am, Grand Prix, Montana, Sunfire 2001-2003 Pontiac Aztek with RPO Codes MN4, MN5, M13, M15, MN3, MN7 or M76 The pressure control solenoid in the above transaxles has changed for the 2003 models. Important: While the physical dimensions will allow usage of the new solenoid in past model transaxles or usage of the old solenoid in 2003 model transaxles, they should not be interchanged. Interchanging of the pressure control solenoids will result in improper shift characteristics, customer dissatisfaction, and needed repeat repairs. When replacing a pressure control solenoid, be sure to use the correct part number. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement > Page 366 Parts are currently available from GMSPO. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set Pressure Regulating Solenoid: All Technical Service Bulletins A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set File In Section: 07 - Transmission/Transaxle Bulletin No.: 0O-07-30-002B Date: July, 2002 TECHNICAL Subject: Slips, Harsh Upshift or Garage Shifts, Launch Shudders, Flares, Erratic Shifts and Intermittent Concerns, DTC P1811 or P0748 Set (Replace Pressure Control Solenoid Valve Assembly) Models: 1997-1999 Buick Riviera 1997-2002 Buick Park Avenue 1998-2002 Buick LeSabre 1999-2002 Buick Regal 2000-2002 Buick Century 2002 Buick Rendezvous 1997-2001 Chevrolet Lumina 1997-2002 Chevrolet Monte Carlo 1999-2002 Chevrolet Venture 2000-2002 Chevrolet Impala 1997-1999 Oldsmobile Eighty Eight 1997-2002 Oldsmobile Silhouette 1998-2002 Oldsmobile Intrigue 2001-2002 Oldsmobile Aurora (3.5L) 1997-2002 Pontiac Bonneville, Grand Prix 1999-2002 Pontiac Transport/Montana 2001-2002 Pontiac Aztek with Hydra-Matic 4T65-E (RPOs MN3, MN7, M15, M76) This bulletin is being revised to add additional models and model years. Please discard Corporate Bulletin Number 00-07-30-002A (Section 07 - Transmission/Transaxle). Condition Some owners of the above vehicles with a HydraMatic 4T65-E transaxle may comment on harsh upshifts or harsh garage shifts, soft shifts, shudders on hard acceleration, or shifts erratic. These conditions may appear intermittently or set a DTC P1811 or P0748. During diagnosis, a low or high line pressure (actual versus desired) may be observed. Cause The above condition may be due to any one of the following which may affect line pressure output: ^ Sediment inside the pressure control (PC) solenoid valve, causing the PC solenoid valve to mechanically bind. ^ Sediment in the valve body, causing the torque signal regulator valve to stick. ^ Incorrect transaxle oil level. Correction Important: Any of the above conditions may be intermittent, therefore, this test should be performed at least three times. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 371 Refer to the Line Pressure Check Procedure in SI, along with the Line Pressure Specification Table shown, to determine if actual versus desired pressures are within the values specified. The Scan Tool is only able to control the PC solenoid valve in PARK and NEUTRAL with the vehicle stopped. This protects the clutches from extremely high or low pressures in DRIVE or REVERSE ranges. Refer to the Line Pressure Specification Table. The pressures in the table assume a temperature of 70°C. The pressure will vary with a change in temperature. If the actual versus desired pressures are not within the values specified, clean the valve body and replace the PC solenoid valve, if necessary. Check the PC solenoid valve actual versus desired pressures to verify the new PC solenoid valve is responding correctly. Refer to the Automatic Transaxle Section of the Service Manual for the proper repair procedure. Line Pressure Check Procedure Tools Required J 21867 Universal Pressure Gauge Set Important: Before performing a line pressure check, verify that the pressure control (PC) solenoid valve is receiving the correct electrical signal from the PCM. 1. Install a Scan Tool. Caution: Keep the brakes applied at all times in order to prevent unexpected vehicle motion. Personal injury may result it the vehicle moves unexpectedly. 2. Start the engine and set the parking brake. 3. Check for a stored Diagnostic Trouble Code (DTC). 4. Repair the vehicle, if necessary. 5. Check the fluid level. Refer to the Transmission Fluid Checking Procedure. 6. Check the manual linkage for proper adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 372 7. Turn the engine OFF. Remove the oil pressure test hole plug and install the J 21867. 8. Put the gear selector in PARK range and set the parking brake. 9. Start the engine and allow the engine to warm up at idle. Notice: Total test running time should not be longer than two minutes, or else transmission damage could occur. 10. Access the PC solenoid valve control test on the Scan Tool. 11. Increase the PC solenoid as shown actual current from 0.0 to 1.0 amps in 0.1 amp increments. Allow the pressure to stabilize for five seconds after each pressure change. Read the corresponding line pressure on the J 21867. 12. Refer to the Line Pressure specification table. Compare the data to the table. 13. If pressure readings differ greatly from the table, refer to Incorrect Line Pressure. 14. Remove the J 21867. 15. Apply sealant, P/N 12345382 (in Canada, P/N 10953489), to the oil pressure test hole plug. Notice: Refer to Fastener Notice in Cautions and Notices. 16. Install the oil pressure test hole plug. Tighten Tighten the oil pressure test hole plug to 12 N.m (106 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 373 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement > Page 379 Parts are currently available from GMSPO. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 384 Refer to the Line Pressure Check Procedure in SI, along with the Line Pressure Specification Table shown, to determine if actual versus desired pressures are within the values specified. The Scan Tool is only able to control the PC solenoid valve in PARK and NEUTRAL with the vehicle stopped. This protects the clutches from extremely high or low pressures in DRIVE or REVERSE ranges. Refer to the Line Pressure Specification Table. The pressures in the table assume a temperature of 70°C. The pressure will vary with a change in temperature. If the actual versus desired pressures are not within the values specified, clean the valve body and replace the PC solenoid valve, if necessary. Check the PC solenoid valve actual versus desired pressures to verify the new PC solenoid valve is responding correctly. Refer to the Automatic Transaxle Section of the Service Manual for the proper repair procedure. Line Pressure Check Procedure Tools Required J 21867 Universal Pressure Gauge Set Important: Before performing a line pressure check, verify that the pressure control (PC) solenoid valve is receiving the correct electrical signal from the PCM. 1. Install a Scan Tool. Caution: Keep the brakes applied at all times in order to prevent unexpected vehicle motion. Personal injury may result it the vehicle moves unexpectedly. 2. Start the engine and set the parking brake. 3. Check for a stored Diagnostic Trouble Code (DTC). 4. Repair the vehicle, if necessary. 5. Check the fluid level. Refer to the Transmission Fluid Checking Procedure. 6. Check the manual linkage for proper adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 385 7. Turn the engine OFF. Remove the oil pressure test hole plug and install the J 21867. 8. Put the gear selector in PARK range and set the parking brake. 9. Start the engine and allow the engine to warm up at idle. Notice: Total test running time should not be longer than two minutes, or else transmission damage could occur. 10. Access the PC solenoid valve control test on the Scan Tool. 11. Increase the PC solenoid as shown actual current from 0.0 to 1.0 amps in 0.1 amp increments. Allow the pressure to stabilize for five seconds after each pressure change. Read the corresponding line pressure on the J 21867. 12. Refer to the Line Pressure specification table. Compare the data to the table. 13. If pressure readings differ greatly from the table, refer to Incorrect Line Pressure. 14. Remove the J 21867. 15. Apply sealant, P/N 12345382 (in Canada, P/N 10953489), to the oil pressure test hole plug. Notice: Refer to Fastener Notice in Cautions and Notices. 16. Install the oil pressure test hole plug. Tighten Tighten the oil pressure test hole plug to 12 N.m (106 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 386 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions Coolant Level Indicator Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 393 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 394 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 395 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 396 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 397 Coolant Level Indicator Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 398 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 399 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 400 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 401 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 402 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 403 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 404 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 405 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 406 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 407 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 408 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 409 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 410 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 411 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 412 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 413 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 414 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 415 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 416 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 417 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 418 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Page 419 Coolant Level Indicator Module: Service and Repair Removal Procedure 1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 2. Partially drain the radiator. Refer to Draining and Filling Cooling System. 3. Disconnect the low coolant module electrical connector. 4. In order to unlock the low coolant module, lift one leg of the snap clip from its locked position and pull outward with a slight twisting motion. Remove the low coolant module. Installation Procedure 1. Lubricate the O-ring seal with coolant. 2. Position the snap clip leg in place. 3. Install the low coolant module. 4. Connect the low coolant module electrical connector. 5. Fill the radiator. Refer to Draining and Filling Cooling System. 6. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 7. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations The Coolant Fan Relays are located in the bottom underhood accessory junction block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor Relay: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 425 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 426 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 427 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 428 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 429 Radiator Cooling Fan Motor Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 430 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 431 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 432 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 433 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 434 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 435 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 436 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 437 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 438 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 439 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 440 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 441 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 442 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 443 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 444 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 445 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 446 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 447 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 448 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 449 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 450 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 451 Cooling Fan Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Specifications Cruise Control Module: Specifications Cruise Control Module to Shock Tower Nuts 2 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Component Locations Cruise Control Module: Component Locations Locations View LH side of the engine compartment, near the strut tower. Left side of the engine compartment, on the strut tower. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Component Locations > Page 458 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions Cruise Control Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 461 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 462 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 463 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 464 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 465 Cruise Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 466 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 467 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 468 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 469 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 470 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 471 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 472 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 473 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 474 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 475 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 476 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 477 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 478 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 479 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 480 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 481 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 482 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 483 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 484 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 485 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 486 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 487 Cruise Control Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 488 Cruise Control Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Description and Operation > General Information Cruise Control Module: Description and Operation General Information The cruise control system uses a cruise control module in order to obtain and hold any desired vehicle cruise speed above a minimum speed of 40 km/h (25 mph). The following 2 components within the module help achieve this function: ^ An electronic controller that performs the following functions: Monitors the vehicle speed. - Monitors the turn signal and the multifunction switch inputs. - Monitors the cruise control release and the brake switch inputs. - Operates the electric stepper motor. ^ A stepper motor which moves an internal band (linked to the throttle lever via the cruise control cable) in response to the controller in order to maintain the desired cruise speed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Description and Operation > General Information > Page 491 Cruise Control Module: Description and Operation Vehicle Speed Sensor The Vehicle Speed Sensor (VSS) is mounted to the automatic transaxle. The VSS provides a low voltage Alternating Current (AC) signal to the Powertrain Control Module (PCM). The PCM converts the AC signal to a pulse width modulated Direct Current (DC) signal. The DC signal is sent to the cruise control module at a rate of 4,000 pulses per mile. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Description and Operation > Page 492 Cruise Control Module: Service and Repair REMOVAL PROCEDURE The cruise control module is mounted to the left strut tower and must be serviced as a complete unit. 1. Remove the cruise control cable from the cruise control module. 2. Remove the electrical connector from the cruise control module. 3. Remove the cruise control module shock tower nuts. 4. Remove the cruise control module. INSTALLATION PROCEDURE 1. Install the cruise control module on the mounting studs located on the shock tower. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Description and Operation > Page 493 2. Install the cruise control module mounting nuts. Tighten Tighten the cruise control module mounting nuts to 2 N.m (18 lb in). 3. Install the electrical connector to the cruise control module. 4. Install the cruise control cable to the cruise control module. 5. Adjust the cruise control cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations BLOWER MOTOR RELAY Locations View The Blower Motor Relay is located in the Blower Motor Control Module (Blower Resistor Assembly) and cannot be serviced separately. The Blower Motor Control Module (Blower Resistor Assembly) is located behind the Instrument Panel (IP), on the right side of the A/C module, attached to the blower motor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 498 Blower Motor Relay: Description and Operation HVAC BLOWER CONTROLS CIRCUIT DESCRIPTION The blower motor is a variable speed motor. The motor operates at a higher rate when voltage is increased to the maximum level. The blower motor resistors reduce the voltage supplied from the A/C FAN fuse (LH IP Accessory Wiring Junction Block) when the blower control is set at low and medium speeds (speeds 1-4). The blower motor relay is energized when the Blower Motor Control is set to the High position. This removes the blower motor resistors from the circuit and battery voltage is then applied directly from the HVAC BLO fuse (RH IP Accessory Wiring Junction Block) to the blower motor though the relay switch contacts. The blower motor then runs at high speed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Top Underhood Electrical Center Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 502 Locations View Part of Underhood Accessory Wiring Junction Block (Top). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 503 Compressor Clutch Relay: Description and Operation The compressor clutch coil is energized through the compressor control relay. This relay is activated by the PCM in A/C modes. The PCM provides cut-off of the relay under certain operating conditions, including wide open throttle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 504 Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Release the retaining clip (1) and remove the engine wiring harness junction block (BOTTOM) cover (2). A/C Compressor Relay (A/C CMPR) (1) {In The Engine Wiring Harness Junction Block} 3. Remove the A/C compressor relay (A/C CMPR) (1) from the engine wiring harness junction block (BOTTOM). INSTALLATION PROCEDURE 1. Install the A/C compressor relay (A/C CM PR) (1) into the engine wiring harness junction block (BOTTOM). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 505 2. Install the engine wiring harness junction block (BOTTOM) cover (2) and secure the retaining clip (1). 3. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions Coolant Level Indicator Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 512 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 513 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 514 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 515 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 516 Coolant Level Indicator Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 517 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 518 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 519 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 520 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 521 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 522 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 523 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 524 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 525 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 526 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 527 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 528 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 529 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 530 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 531 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 532 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 533 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 534 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 535 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 536 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 537 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Page 538 Coolant Level Indicator Module: Service and Repair Removal Procedure 1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 2. Partially drain the radiator. Refer to Draining and Filling Cooling System. 3. Disconnect the low coolant module electrical connector. 4. In order to unlock the low coolant module, lift one leg of the snap clip from its locked position and pull outward with a slight twisting motion. Remove the low coolant module. Installation Procedure 1. Lubricate the O-ring seal with coolant. 2. Position the snap clip leg in place. 3. Install the low coolant module. 4. Connect the low coolant module electrical connector. 5. Fill the radiator. Refer to Draining and Filling Cooling System. 6. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 7. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations Backup Lamp Relay: Locations RH Instrument Panel Fuse Block Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 543 Locations View In the RH instrument panel Fuse Block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Relay: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 546 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 547 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 548 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 549 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 550 Backup Lamp Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 551 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 552 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 553 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 554 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 555 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 556 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 557 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 558 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 559 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 560 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 561 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 562 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 563 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 564 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 565 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 566 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 567 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 568 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 569 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 570 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 571 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations Daytime Running Lamp Relay: Locations Top Underhood Electrical Center Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 575 Locations View Part of Underhood Accessory Wiring Junction Block (Top). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Description and Operation > Park and License Lamps Exterior Lighting Module: Description and Operation Park and License Lamps The park and license lamps are controlled by the PARK LAMP relay in the RH I/P accessory wiring junction block. Both the coil and the switched sides of the relay receive B+ at all times. When the headlamp switch is turned to the PARK position, ground is supplied through the headlamp switch to the BCM through the park lamp switch input circuit. The BCM then applies a ground through the park lamp relay coil control circuit to the PARK LAMP relay. This energizes the relay, closing the switch contact and applies B+ to both the REAR PARK LAMP fuse and the FRONT PARK LAMP fuse. B+ is then applied through the park lamps ON circuit to the front and rear park lamps and the license lamps turning them on. The park lamps and license lamps receive ground at all times. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Description and Operation > Park and License Lamps > Page 580 Exterior Lighting Module: Description and Operation Hazard Lamps The hazard lamps receive B+ at all times through the HAZARD SWITCH fuse to the hazard lamp/turn signal flasher. When the hazard switch is placed in the HAZARD position, B+ is applied to all of the turn lamps and turn indicators simultaneously flashing them on and off. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Description and Operation > Park and License Lamps > Page 581 Exterior Lighting Module: Description and Operation Stop Lamps The stop lamps receive B+ at all times through the BRAKE SWITCH fuse to the stop lamp switch. When the stop lamp switch is closed, B+ is applied to the stop lamp switch output circuit to all the stop lamps turning them on. The stop lamps receive ground at all times. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Description and Operation > Park and License Lamps > Page 582 Exterior Lighting Module: Description and Operation Backup Lights Circuit Description The BACKUP LAMPS Relay in the RH I/P Accessory Wiring Junction Block receives B+ at all the times for the coil side from the DIC/RKE fuse. B+ for the switched side of the relay is supplied from the B/U LAMP fuse. When the vehicle is placed in REVERSE, a class 2 signal is sent to the BCM. The BCM then applies a ground through the backup lamp relay coil feed control circuit to the backup lamps relay. This energizes the relay and allows B+ to be applied to the backup lamps turning them on. The backup lamps receive a constant ground signal Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Top Underhood Electrical Center Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 586 Locations View Part of Underhood Accessory Wiring Junction Block (Top). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations LH Instrument Panel Fuse Block Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 590 Locations View Inside the LH instrument panel fuse block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Top Underhood Electrical Center Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 594 Locations View Part of Underhood Accessory Wiring Junction Block (Top). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 595 Horn Relay: Service and Repair REMOVAL PROCEDURE 1. Open the hood. 2. Turn the underhood electrical center mounting knob counterclockwise and pull outward to remove the underhood electrical center cover. 3. Remove the horn relay (1) from the underhood electrical center. INSTALLATION PROCEDURE 1. Align the horn relay (1) to the underhood electrical center. 2. Apply pressure to the horn relay until fully seated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 596 3. Align the underhood electrical center cover to the underhood electrical center and turn the mounting knob clockwise until fully seated. 4. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations RH Instrument Panel Fuse Block Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 600 Locations View In the RH instrument panel Fuse Block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Body Control Module: Customer Interest BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 611 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 Body Control Module: Customer Interest Body Control Module - MIL ON/DTCs B2647/B2648 File In Section: 08 - Body and Accessories Bulletin No.: 00-08-47-002 Date: September, 2000 Subject: Service Vehicle Soon (SVS) Message, DTC B2647 and/or B2648 Set (Replace Body Control Module) Models: 2000 Chevrolet Impala, Monte Carlo Built Prior to VIN Breakpoint Y9255551 Condition Some customers may comment about a "Service Vehicle Soon" message displayed, which may or may not store diagnostic codes (DTCs) B2647 and/or B2648. Cause The headlamp auto control ambient light sensor sends a brief voltage spike to the body control module (BCM) during engine crank, which may be detected as a fault by the BCM. This may initiate the SVS message. This voltage is considered a normal condition of the ambient light sensor. Correction Replace the body control module (BCM) to correct this condition. BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: ^ The vehicle will not be protected against theft by the Passlock(TM) system. ^ The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 616 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (* )You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 617 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 47. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 48. Select Set Options and press Enter. 49. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 50. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 51. Select Set Option Configuration and press Enter. 52. Press the key under the highlighted Done area of the Tech 2 display. 53. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 54. Exit back to the Main Menu screen. 55. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 56. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 57. Turn the ignition switch to OFF and wait 15 seconds. 58. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 59. The Security and Battery messages will begin toggling. 60. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 61. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 618 62. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 63. The Security and Battery messages will begin toggling. 64. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 65. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 66. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 67. The Security and Battery messages will begin toggling. 68. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 69. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 70. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Parts Information The BCM part number has not changed, but the new BCM should have a code GMAB139 or higher on the label. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Body Control Module: All Technical Service Bulletins BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 624 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-52-001 > Feb > 04 > Keyless Entry - BCM Set-Up Programming Body Control Module: All Technical Service Bulletins Keyless Entry - BCM Set-Up Programming Bulletin No.: 04-08-52-001 Date: February 25, 2004 INFORMATION Subject: Set-up/Programming BCM for Remote Keyless Entry (RKE) Models: 2000-2004 Chevrolet Impala, Monte Carlo In the past, when replacing the BCM on the above listed vehicles, the module had to be set-up to ensure the RKE was initiated. The RKE option RPO may not have been called out individually on the SPID label when the RKE option was part of an option package. This would often lead to this option being missed during BCM set-up and leading to an inoperative RKE feature. The new BCM, P/N 10350647, currently available, will automatically toggle the RKE function on during initiation of the module. Therefore, it is no longer necessary to turn on the RKE. Just leave it on regardless if the vehicle is equipped with RKE or not. This will prevent an incorrect set-up causing this feature to become inoperative. This new BCM will also remedy a situation where some older BCMs would not remember the horn chirp setting, short or long, after going into sleep mode. Also, this new BCM will not lock the settings until after 32 key cycles compared to 15 key cycles on older BCMs. So, if a mistake is made during the initial set-up, you can re-set the module. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 Body Control Module: All Technical Service Bulletins Body Control Module - MIL ON/DTCs B2647/B2648 File In Section: 08 - Body and Accessories Bulletin No.: 00-08-47-002 Date: September, 2000 Subject: Service Vehicle Soon (SVS) Message, DTC B2647 and/or B2648 Set (Replace Body Control Module) Models: 2000 Chevrolet Impala, Monte Carlo Built Prior to VIN Breakpoint Y9255551 Condition Some customers may comment about a "Service Vehicle Soon" message displayed, which may or may not store diagnostic codes (DTCs) B2647 and/or B2648. Cause The headlamp auto control ambient light sensor sends a brief voltage spike to the body control module (BCM) during engine crank, which may be detected as a fault by the BCM. This may initiate the SVS message. This voltage is considered a normal condition of the ambient light sensor. Correction Replace the body control module (BCM) to correct this condition. BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: ^ The vehicle will not be protected against theft by the Passlock(TM) system. ^ The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 633 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (* )You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 634 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 47. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 48. Select Set Options and press Enter. 49. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 50. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 51. Select Set Option Configuration and press Enter. 52. Press the key under the highlighted Done area of the Tech 2 display. 53. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 54. Exit back to the Main Menu screen. 55. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 56. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 57. Turn the ignition switch to OFF and wait 15 seconds. 58. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 59. The Security and Battery messages will begin toggling. 60. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 61. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 635 62. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 63. The Security and Battery messages will begin toggling. 64. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 65. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 66. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 67. The Security and Battery messages will begin toggling. 68. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 69. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 70. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Parts Information The BCM part number has not changed, but the new BCM should have a code GMAB139 or higher on the label. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure Body Control Module: All Technical Service Bulletins BCM - Related Service, Theft Deterrent Relearn Procedure File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-057A Date: May, 2000 INFORMATION Subject: Body Control Module (BCM) Related Service, Theft Deterrent Re-Learn Procedure Models: 2000 Chevrolet Impala, Monte Carlo This bulletin is being revised to update the service procedure and the labor time information. Please discard Corporate Bulletin Number 99-06-O4-057 (Section 6 - Engine/Propulsion System). BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: - The vehicle will not be protected against theft by the Passlock(TM) system. - The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 640 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (*) You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 641 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. 47. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 48. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 49. Select Set Options and press Enter. 50. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 51. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 52. Select Set Option Configuration and press Enter. 53. Press the key under the highlighted Done area of the Tech 2 display. 54. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 55. Exit back to the Main Menu screen. 56. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 57. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 58. Turn the ignition switch to OFF and wait 15 seconds. 59. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 60. The Security and Battery messages will begin toggling. 61. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 62. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 63. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 64. The Security and Battery messages will begin toggling. 65. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 66. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 67. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 642 release the ignition switch to the RUN position (the engine will not crank). 68. The Security and Battery messages will begin toggling. 69. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 70. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 71. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N4800 Computer (Control), Body - 1.1 hrs Replace and Program Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn Body Control Module: All Technical Service Bulletins BCM - Related Service. Theft Deterrent Relearn File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-057 Date: November, 1999 INFORMATION Subject: Body Control Module (BCM) Related Service, Theft Deterrent Re-Learn Procedure Models: 2000 Chevrolet Impala, Monte Carlo BCM replacement requires that a programming function be performed. If the BCM is not properly programmed, the vehicle may not start because the Theft Lock System will be enabled. Important: If the module is not properly programmed within twenty (20) key cycles (including the VIN), the module will lock and programming will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reprogrammed. When replacing the BCM, a critical component of the procedure requires a programming of the BCM. To program the BCM, follow all of the steps in the procedure listed. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "setup new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: - The vehicle will not be protected against theft by the Passlock(TM) system. - The engine will not crank or start. Programming of the BCM requires the use of the Tech 2 scan tool. 1. Insure that the key (or ignition) switch is in the LOCK position with the ignition off. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the key to the ON position. 4. The following items all refer to the Tech 2 scan tool inputs: ^ Select Diagnostics and answer the questions when prompted by the Tech 2. ^ Select Body Control Module (BCM). ^ Select Special Functions. ^ Select New VIN and input the required data. ^ Exit back to the Special Functions menu. 5. Select BCM Programming. 6. Press the YES key when the following message is displayed: Do you want to setup a body control module? 7. The Tech 2 will then display the following message: Now setting up the New Body Control Module. 8. When the BCM has been setup successfully, the Tech 2 will display this message: Body Control Module setup is complete. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 647 THIS MEANS THAT THE TECH 2 HAS SET THE BCM TO ACCEPT THE CORRECT INFORMATION. THIS IS NOT THE END OF THE PROGRAMMING PROCEDURE. 9. Exit back to the Special Functions menu. 10. Select Set Options. 11. Input all of the required data as prompted by the Tech 2. 12. Exit back to the Special Functions menu. 13. Select Option Configuration. 14. Input all of the required data as prompted by the Tech 2. 15. When the BCM, VIN, Point of Sale and option configuration have been entered, proceed with the Theft Deterrent Re-Learn Procedure. IF THE TECH 2 DISPLAYS "UNABLE TO PROGRAM THE BCM", THE BCM IS LOCKED. TWENTY KEY CYCLES HAVE OCCURRED SINCE THE MODULE WAS INSTALLED AND VOLTAGE WAS SUPPLIED TO THE MODULE SO THE MODULE MUST BE REPLACED AND THIS PROCEDURE MUST BE REPEATED IN ITS ENTIRETY. Important: Programming of the BCM removes any personalization settings the customer may have previously set. Inform the customer the personalization settings will have to be reset. Theft Deterrent Re-Learn Important: Perform the Theft Deterrent Re-Learn Procedure when one or more of the following conditions has occurred. - The BCM has been replaced or re-programmed (Set-up) (Configured). - The ignition key cylinder assembly has been replaced. The Theft Deterrent Re-Learn Procedure can be accomplished two different ways depending on the equipment you have available. ^ Using The Techline equipment and the Tech 2 scan tool. ^ Without Techline Equipment of any kind. This procedure takes 30 minutes and must not be shortened. USING TECHLINE EQUIPMENT AND THE TECH 2 SCAN TOOL 1. If you disconnected the scan tool from the DLC, perform the following 3 steps. If it is still connected, proceed to step 5. 2. Ensure that the key (or ignition) switch is in the LOCK position with the ignition off. 3. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 4. Turn the key to the ON position. 5. From the Main Menu screen of the Tech 2, select Service Programming. 6. Enter the requested information. 7. Select Request Info. 8. When the Tech 2 finishes gathering the information, disconnect the Tech 2 from the DLC. 9. Connect the Tech 2 to the Techline terminal. 10. Select Service Programming System (SPS). 11 Select Terminal to Tech 2 programming. 12. Select Done. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 648 13. Follow the instructions displayed on the Techline terminal for hand-held communications set-up screen. 14. Select Theft Module Re-Learn. 15. Select program at the summary screen. The terminal will now download information into the Tech 2. 16. Disconnect the Tech 2 from the Techline terminal. 17. Re-connect the Tech 2 to the DLC. 18. At the Scan Tool Main Menu, select Service Programming. 19. Answer the Tech 2 question. 20. Select Re-Learn. 21. The PCM and BCM are now prepared for the Re-Learn procedure to begin. 22. An internal security timer will now start. The security timer is 10 minutes in duration. Important: During this 10 minute period, the scan tool must NOT be disconnected from the vehicle. Does the Tech 2 display any kind of message telling you to proceed? 23. Turn the ignition switch to the OFF position. 24. Start the engine. The engine should start and continue to run. 25. The Theft Re-Learn procedure is complete. Look for any DTCs which may have been set during this procedure. If codes were set, clear them now. Remove the Tech 2 from the vehicle. WITHOUT TECHLINE EQUIPMENT OF ANY KIND This procedure takes 30 minutes and must not be shortened. 1. Ensure that the battery is fully charged before starting this procedure. 2. Turn the ignition switch to the OFF position. 3. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 4. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 5. Turn the ignition switch to the OFF position for 5 seconds. 6. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 7. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 8. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 9. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 10. Turn the ignition switch to the OFF position for 5 seconds. 11. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will now start. 12. Using the Tech 2, look for a Clear All Trouble Codes (DTCs). Warranty Information For vehicles repaired under warranty, use: Operation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 649 Labor Description Labor Time N4800 Computer (Control), Body - 0.7 hr Replace and Program Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 04-08-52-001 > Feb > 04 > Keyless Entry - BCM Set-Up Programming Body Control Module: All Technical Service Bulletins Keyless Entry - BCM Set-Up Programming Bulletin No.: 04-08-52-001 Date: February 25, 2004 INFORMATION Subject: Set-up/Programming BCM for Remote Keyless Entry (RKE) Models: 2000-2004 Chevrolet Impala, Monte Carlo In the past, when replacing the BCM on the above listed vehicles, the module had to be set-up to ensure the RKE was initiated. The RKE option RPO may not have been called out individually on the SPID label when the RKE option was part of an option package. This would often lead to this option being missed during BCM set-up and leading to an inoperative RKE feature. The new BCM, P/N 10350647, currently available, will automatically toggle the RKE function on during initiation of the module. Therefore, it is no longer necessary to turn on the RKE. Just leave it on regardless if the vehicle is equipped with RKE or not. This will prevent an incorrect set-up causing this feature to become inoperative. This new BCM will also remedy a situation where some older BCMs would not remember the horn chirp setting, short or long, after going into sleep mode. Also, this new BCM will not lock the settings until after 32 key cycles compared to 15 key cycles on older BCMs. So, if a mistake is made during the initial set-up, you can re-set the module. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure Body Control Module: All Technical Service Bulletins BCM - Related Service, Theft Deterrent Relearn Procedure File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-057A Date: May, 2000 INFORMATION Subject: Body Control Module (BCM) Related Service, Theft Deterrent Re-Learn Procedure Models: 2000 Chevrolet Impala, Monte Carlo This bulletin is being revised to update the service procedure and the labor time information. Please discard Corporate Bulletin Number 99-06-O4-057 (Section 6 - Engine/Propulsion System). BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: - The vehicle will not be protected against theft by the Passlock(TM) system. - The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 659 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (*) You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 660 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. 47. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 48. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 49. Select Set Options and press Enter. 50. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 51. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 52. Select Set Option Configuration and press Enter. 53. Press the key under the highlighted Done area of the Tech 2 display. 54. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 55. Exit back to the Main Menu screen. 56. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 57. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 58. Turn the ignition switch to OFF and wait 15 seconds. 59. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 60. The Security and Battery messages will begin toggling. 61. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 62. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 63. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 64. The Security and Battery messages will begin toggling. 65. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 66. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 67. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 661 release the ignition switch to the RUN position (the engine will not crank). 68. The Security and Battery messages will begin toggling. 69. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 70. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 71. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N4800 Computer (Control), Body - 1.1 hrs Replace and Program Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn Body Control Module: All Technical Service Bulletins BCM - Related Service. Theft Deterrent Relearn File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-057 Date: November, 1999 INFORMATION Subject: Body Control Module (BCM) Related Service, Theft Deterrent Re-Learn Procedure Models: 2000 Chevrolet Impala, Monte Carlo BCM replacement requires that a programming function be performed. If the BCM is not properly programmed, the vehicle may not start because the Theft Lock System will be enabled. Important: If the module is not properly programmed within twenty (20) key cycles (including the VIN), the module will lock and programming will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reprogrammed. When replacing the BCM, a critical component of the procedure requires a programming of the BCM. To program the BCM, follow all of the steps in the procedure listed. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "setup new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: - The vehicle will not be protected against theft by the Passlock(TM) system. - The engine will not crank or start. Programming of the BCM requires the use of the Tech 2 scan tool. 1. Insure that the key (or ignition) switch is in the LOCK position with the ignition off. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the key to the ON position. 4. The following items all refer to the Tech 2 scan tool inputs: ^ Select Diagnostics and answer the questions when prompted by the Tech 2. ^ Select Body Control Module (BCM). ^ Select Special Functions. ^ Select New VIN and input the required data. ^ Exit back to the Special Functions menu. 5. Select BCM Programming. 6. Press the YES key when the following message is displayed: Do you want to setup a body control module? 7. The Tech 2 will then display the following message: Now setting up the New Body Control Module. 8. When the BCM has been setup successfully, the Tech 2 will display this message: Body Control Module setup is complete. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 666 THIS MEANS THAT THE TECH 2 HAS SET THE BCM TO ACCEPT THE CORRECT INFORMATION. THIS IS NOT THE END OF THE PROGRAMMING PROCEDURE. 9. Exit back to the Special Functions menu. 10. Select Set Options. 11. Input all of the required data as prompted by the Tech 2. 12. Exit back to the Special Functions menu. 13. Select Option Configuration. 14. Input all of the required data as prompted by the Tech 2. 15. When the BCM, VIN, Point of Sale and option configuration have been entered, proceed with the Theft Deterrent Re-Learn Procedure. IF THE TECH 2 DISPLAYS "UNABLE TO PROGRAM THE BCM", THE BCM IS LOCKED. TWENTY KEY CYCLES HAVE OCCURRED SINCE THE MODULE WAS INSTALLED AND VOLTAGE WAS SUPPLIED TO THE MODULE SO THE MODULE MUST BE REPLACED AND THIS PROCEDURE MUST BE REPEATED IN ITS ENTIRETY. Important: Programming of the BCM removes any personalization settings the customer may have previously set. Inform the customer the personalization settings will have to be reset. Theft Deterrent Re-Learn Important: Perform the Theft Deterrent Re-Learn Procedure when one or more of the following conditions has occurred. - The BCM has been replaced or re-programmed (Set-up) (Configured). - The ignition key cylinder assembly has been replaced. The Theft Deterrent Re-Learn Procedure can be accomplished two different ways depending on the equipment you have available. ^ Using The Techline equipment and the Tech 2 scan tool. ^ Without Techline Equipment of any kind. This procedure takes 30 minutes and must not be shortened. USING TECHLINE EQUIPMENT AND THE TECH 2 SCAN TOOL 1. If you disconnected the scan tool from the DLC, perform the following 3 steps. If it is still connected, proceed to step 5. 2. Ensure that the key (or ignition) switch is in the LOCK position with the ignition off. 3. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 4. Turn the key to the ON position. 5. From the Main Menu screen of the Tech 2, select Service Programming. 6. Enter the requested information. 7. Select Request Info. 8. When the Tech 2 finishes gathering the information, disconnect the Tech 2 from the DLC. 9. Connect the Tech 2 to the Techline terminal. 10. Select Service Programming System (SPS). 11 Select Terminal to Tech 2 programming. 12. Select Done. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 667 13. Follow the instructions displayed on the Techline terminal for hand-held communications set-up screen. 14. Select Theft Module Re-Learn. 15. Select program at the summary screen. The terminal will now download information into the Tech 2. 16. Disconnect the Tech 2 from the Techline terminal. 17. Re-connect the Tech 2 to the DLC. 18. At the Scan Tool Main Menu, select Service Programming. 19. Answer the Tech 2 question. 20. Select Re-Learn. 21. The PCM and BCM are now prepared for the Re-Learn procedure to begin. 22. An internal security timer will now start. The security timer is 10 minutes in duration. Important: During this 10 minute period, the scan tool must NOT be disconnected from the vehicle. Does the Tech 2 display any kind of message telling you to proceed? 23. Turn the ignition switch to the OFF position. 24. Start the engine. The engine should start and continue to run. 25. The Theft Re-Learn procedure is complete. Look for any DTCs which may have been set during this procedure. If codes were set, clear them now. Remove the Tech 2 from the vehicle. WITHOUT TECHLINE EQUIPMENT OF ANY KIND This procedure takes 30 minutes and must not be shortened. 1. Ensure that the battery is fully charged before starting this procedure. 2. Turn the ignition switch to the OFF position. 3. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 4. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 5. Turn the ignition switch to the OFF position for 5 seconds. 6. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 7. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 8. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 9. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 10. Turn the ignition switch to the OFF position for 5 seconds. 11. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will now start. 12. Using the Tech 2, look for a Clear All Trouble Codes (DTCs). Warranty Information For vehicles repaired under warranty, use: Operation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 668 Labor Description Labor Time N4800 Computer (Control), Body - 0.7 hr Replace and Program Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Body Control Module: Component Locations Locations View LH side of the instrument panel, above parking brake. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 671 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 674 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 675 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 676 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 677 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 678 Body Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 679 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 680 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 681 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 682 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 683 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 684 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 685 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 686 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 687 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 688 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 689 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 690 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 691 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 692 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 693 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 694 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 695 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 696 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 697 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 698 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 699 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 700 Body Control Module: Connector Views Body Control Module, C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 701 Body Control Module, C2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 702 Body Control Module, C3 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 703 Body Control Module: Electrical Diagrams Body Control Module Schematics: Door Lock Switches, LH Front Door Lock Assembly Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 704 Body Control Module Schematics: DRL Relay, Backup Relay And Ambient Light Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 705 Body Control Module Schematics: Headlamp Switch, Ignition Key Alarm Switch, Surveillance Switch And Park Brake Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 706 Body Control Module Schematics: Headlamp Dimmer Switch, Headlamp Relay, Parklamp Relay Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 707 Body Control Module Schematics: HORN Relay FOG LP Relay And Fog Lamp Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 708 Body Control Module Schematics: Interior Lights (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 709 Body Control Module Schematics: Interior Lights (Part 2 of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 710 Body Control Module Schematics: Power, Grounds and RAP Relay Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 711 Body Control Module Schematics: Brake Transaxle Shift Interlock Control, Rear Compartment Lid Release And Remote Control Door Lock Receiver Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 712 Body Control Schematics: Rear Defog Relay, Door Lock Cylinder Switches Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 713 Body Control Module Schematics: RF And Rear Door Lock Assemblys Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 714 Body Control Module Schematics: SEO Rear Compartment Lid Relay Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 715 Body Control Module Schematics: Traction Control Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description Body Control Module: Description and Operation Circuit Description General Information The Body Control Module (BCM) is capable of accomplishing multiple body control functions. Components directly connected to the BCM are controlled by the BCM's outputs. The BCM can control its outputs based on input information it obtains from sensors and switches that are directly connected to the BCM, or by borrowing information from other vehicle systems connected to the Class 2 serial data link. The BCM evaluates this information and controls certain body systems by commanding an output on or off. The BCM is also capable of commanding other vehicle systems to control functions that are not directly wired and/or controlled by the BCM. The BCM accomplishes this task by sending specific messages on the Class 2 serial data link. The vehicle system capable of performing such function will respond to the BCM message. The BCM performs these functions: ^ Audible warnings. ^ Interior lighting. ^ Automatic door locks. ^ Keyless entry (AUO option) ^ Passlock theft deterrent. ^ Content Theft (UA6 option) ^ Retained Accessory Power (RAP) RPO AUO, UA6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Audible Warnings ^ Key in ignition reminder. ^ Fasten seat belt reminder. ^ Fasten belts indicator control. ^ Parking brake reminder. ^ Turn signal reminder. ^ Low fuel reminder. ^ Headlamps ON reminder. ^ Last door closed locking confirmation. ^ Feature customization. Interior Lighting ^ Interior illumination control. ^ Delayed illumination. ^ Illuminated entry. ^ Exit illumination. ^ Theater dimming. ^ Keyless entry unlock illumination. ^ Inadvertent load (battery rundown) protection. Automatic Door Locks ^ All door unlock. ^ All door lock. ^ Last door closed locking. ^ Lockout prevention. ^ Lockout prevention override. ^ Shift into PARK unlock. ^ Shift out of PARK lock. ^ Remote driver door unlock. ^ Remote all door unlock. ^ Remote all door lock. Keyless Entry ^ Remote driver door unlock. ^ Remote all door unlock. ^ Remote all door lock. ^ Remote activation verification. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 718 ^ Remote alarm. ^ Feature customization of remote activation verification. BCM Inputs The following components provide direct input to the BCM, plus other systems can use this input information in order to carry out certain functions: ^ A/C Request: Provides the BCM with a request signal to command the A/C compressor through the PCM via Class 2 serial data. ^ BCM Ground: Provides ground for BCM operation. ^ BCM Power: Provides voltage for BCM operation. ^ Courtesy Lights On: Provides the driver the ability to request illumination of the vehicle interior. ^ Crank Signal: Determines when the ignition switch is in the start position. ^ Dome Lamp Switch Input: Determines when the dome lamp switch (Headlamp Switch) is closed to request the dome lamp on. ^ Door Lock Switch: Door lock switch request to lock and unlock the vehicle doors. ^ Door Locks: Provides voltage for door lock actuator operation. ^ Door Open: Provides door ajar status. ^ Driver Door Open: Allows certain chime functions when the driver's door is open. ^ DRL Signal Low: This input provides the BCM with Information through an ambient light sensor for the DRL feature. ^ Exterior Lamps Off: Determines when the headlamp switch is in the OFF position. ^ Fog Lamp Switch input: This input provides the BCM with a request for fog lamps through a momentary switch connected to ground. ^ Headlamp Switch Input: Determines when the Headlamp switch is closed to request the headlamps on. ^ High Beam: Determines the status of the headlamp dimmer switch, so the BCM can send the instrument cluster a message, via Class 2, to turn on the high beam indicator. ^ Ignition 0 Signal: Determines when the ignition switch is in ACCESSORY, ON or START position. ^ Ignition 1 Signal: Determines when the ignition switch is in the ON and START positions. ^ Key In Ignition: Determines when the key is fully inserted in the ignition key cylinder. ^ Key Unlock: Determines the status of the door lock cylinder switches for content theft. ^ Lamp Request: This input requests the BCM to energize the Battery Rundown Protection relay after the car has been turned off and all the doors have been closed, so the interior lights can be turned on. ^ Park Brake Applied: Determines when the parking brake is applied. ^ Park Lamp Switch Input: Determines when the park lamp switch (Headlamp Switch) is closed to request the park lamps on. ^ Passlock Sensor Data: Reads the Passlock sensor security code. ^ Rear Compartment Ajar: Determines if the rear decklid is open or closed. ^ Rear Compartment Release: This input requests the BCM to open the rear compartment lid. ^ RFA Link: Provides an interface allowing the transfer of keyless entry information from the Remote Control Door Lock Receiver (RCDLR). ^ Serial Data: provides an interface with the PCM, EBCM, Radio, SDM, DIC and the IPC through the Class 2 serial data link. ^ Surveillance Switch Input: Determines when the surveillance switch is closed to request the surveillance mode. ^ Traction Control Request: This input provides the BCM with a request for Traction Control through a momentary switch connected to ground. BCM Outputs The BCM directly controls these outputs, plus other systems may request the BCM to control these outputs for certain functions: ^ All Door Lock: This output supplies voltage to the door lock actuators when the doors are commanded to lock. This output also supplies ground to all the door lock actuators when the doors are commanded to unlock. ^ Backup Lamp Relay Control: Provides ground to the Backup LP relay control circuit. ^ BTSI Solenoid Control: Provides ground to the Brake Transaxle Shift Interlock Control Solenoid. ^ Door Unlock: This output supplies voltage to the door lock actuators (except the driver door lock actuator) when the doors are commanded to unlock. This output also supplies ground to all the door lock actuators (except the driver door lock actuator) when the doors are commanded to lock. ^ Driver Door Unlock: This output supplies voltage to the driver door lock actuators when the doors are commanded to unlock. This output also supplies ground to the driver door lock actuator when the doors are commanded to lock. ^ DRL Relay Control: Provides ground to the DRL relay control circuit. ^ DRL 5 V Reference: Provides 5 Volts to the ambient light sensor. ^ Inadvertent Load Relay Control Output: Supplies ground to the battery rundown protection relay providing an inadvertent load (battery rundown) protection. ^ Fog Lamp Enable Control: Sends a ground signal to the fog lamp switch when the ignition switch on; this action enables the fog lamp switch. The fog lamps turn on when the fog lamp switch is enabled by the BCM. ^ Headlamp Relay Control: Provides ground to the Headlamp relay control circuit. ^ Horn: Sends a ground signal to the horn relay, sounding the horn for the keyless entry alarm function or the content theft system. ^ Inadvertent Relay Control: Provides ground to the Battery Rundown Protection relay control circuit. ^ Interior Dimming: Controls the voltage to the interior lights dimming system. ^ Load Management Control: Provides voltage to the Rear Defogger relay control circuit and the Heated Seats. ^ Park Lamp Relay Control: Provides ground to the Park Lamp relay control circuit. ^ Passlock Sensor Power: Provides B+ for Passlock sensor operation. ^ Passlock Sensor Ground: Provides ground to the Passlock sensor. ^ RAP Relay Control: Provides voltage to the RAP relay control feed circuit. ^ Rear Compartment Lid Release Output: Provides ground to Rear Compartment Lid Release Actuator. ^ RFA Link: Provides an interface allowing the transfer of keyless entry information to the Remote Control Door Lock Receiver (RCDLR). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 719 ^ Serial Data: provides an interface with the PCM, EBCM, Radio, SDM, DIC and the IPC through the Class 2 serial data link. ^ Theater Dimming 1 Control: Supplies ground to activate the Footwell lamps. ^ Theater Dimming 2 Control: Supplies ground to activate the inside rear view mirror lamps, non SEO dome lamp, and the roof rail courtesy/reading lamps. BCM Wake-Up/Sleep State The BCM performs its functions in the wake-up state. The BCM enters the sleep state when active control or monitoring of system malfunctions has stopped, or when the BCM is idling. The BCM must detect certain wake-up inputs before entering the wake-up state. The BCM monitors its inputs during the sleep state, allowing the BCM to switch between the two states, awake or asleep. The BCM enters the wake-up state when receiving activity on any of these inputs: ^ I/P dimmer switch. ^ Door lock (ajar) switch. ^ Door lock switch. ^ A keyless entry system signal. ^ Inadvertent power (battery rundown) protection transition. ^ The ignition is turned to the LOCK, ACCESSORY or the ON position. The sleep state is when the BCM has stopped active control and monitoring of system functions and has become idle again. For the BCM to enter the wake-up state, the BCM must detect a wake-up condition, mentioned previously. These conditions are called wake-up inputs that cause the BCM to change from a sleep to a wake-up state and begin active control and monitoring. The BCM has the ability to monitor for these wake-up inputs in the sleep state. The BCM enters the sleep state when all of these conditions exist: ^ No activity on the Class 2 serial data link. ^ The ignition switch is in the OFF position. ^ The BCM is not commanding any outputs. ^ No delay timers are actively counting (during theft deterrent re-learn). ^ No wake-up inputs are present. Content Theft (UA6 Option) The Body Control Module features a content theft deterrent system which is designed to defer vehicle vandalism and theft. The content theft deterrent system performs these functions: ^ Flashes the headlamps ^ Sounds the horns ^ Disables fuel delivery to the engine The BCM monitors the following: ^ Status of the doors ^ Lock cylinders ^ Rear compartment lid ^ Power door locks ^ The keyless entry system The BCM operates the headlamps, horns and the theft deterrent indicator, thats in the radio, according to the mode of operation the system is in. The BCM also communicates a fuel enable signal to the Powertrain Control Module (PCM) when the system is armed. Refer to Content Theft Deterrent (CTD) Operation in Theft Deterrent for more information. RPO UA6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Miscellaneous Functions ^ BRAKE indicator lamp control: The BCM controls the state of the BRAKE indicator lamp based on the status of the parking brake switch by sending a message to the instrument cluster via the Class 2 serial data link. ^ Fog lamp enable control. The BCM controls fog lamp operation, based on the status of the ignition switch. ^ Day/night mode sensing: The BCM determines the ambient light operating mode. The BCM then communicates the information to the Instrument Cluster and Powertrain Control Module (PCM) via the Class 2 serial data link. Passlock Theft Deterrent The Passlock is a vehicle theft deterrent system. The Passlock theft deterrent system contains a Passlock sensor. The Passlock sensor is part of the ignition lock cylinder assembly. The Body Control Module (BCM) provides power and ground to the Passlock sensor. The Passlock sensor interfaces with the BCM through the Passlock detection circuit. When turning the ignition switch to the start position with the proper key, the Passlock sensor generates an analog voltage signal. This signal is sent through the Passlock detecting circuit. This analog voltage signal is of a specific value to the vehicle, and varies from vehicle to vehicle. When attempting to start the engine, the BCM compares a preset stored analog voltage value with the signal coming from the sensor. Because both values Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 720 match, the BCM sends a fuel enable password via the Class 2 serial data link to the Powertrain Control Module (PCM). As a result, the PCM enables the crank relay, and allows fuel delivery to the engine. When attempting to start the engine by means other than using the proper key in the ignition switch, the Passlock sensor sends an analog voltage signal of a different value. The BCM compares the preset stored analog voltage value with the signal coming from the sensor. Because both values do not match, the BCM sends a fuel disable password via the Class 2 serial data link to the Powertrain Control Module (PCM). As a result, the PCM disables the crank relay, and does not allow fuel delivery to the engine. Power Requirements The BCM has three main voltage feeds and two grounds. The voltage feed circuits are used to provide power for the BCM's logic, courtesy lights, internal driver operation and the door locks. Retained Accessory Power (RAP) The Accessory Power (RAP) feature allows the operation of the following functions for 10 minutes (or until a vehicle door opens) after the ignition switch has been turned from the ON or ACCESSORY position to the LOCK position: ^ The radio ^ The power windows ^ The power sunroof (if equipped) Refer to Keyless Entry System Operation in Retained Accessory Power (RAP) for more information. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 721 Body Control Module: Description and Operation System Operation General Information The Body Control Module (BCM) is capable of accomplishing multiple body control functions. Components directly connected to the BCM are controlled by the BCM's outputs. The BCM can control its outputs based on input information it obtains from sensors and switches that are directly connected to the BCM, or by borrowing information from other vehicle systems connected to the Class 2 serial data link. The BCM evaluates this information and controls certain body systems by commanding an output on or off. The BCM is also capable of commanding other vehicle systems to control functions that are not directly wired and/or controlled by the BCM. The BCM accomplishes this task by sending specific messages on the Class 2 serial data link. The vehicle system capable of performing such function will respond to the BCM message. The BCM performs these functions: ^ Audible warnings. ^ Interior lighting. ^ Automatic door locks. ^ Keyless entry (AUO option) ^ Passlock theft deterrent. ^ Content Theft (UA6 option) ^ Retained Accessory Power (RAP) RPO UA6, AUO: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Audible Warnings ^ Key in ignition reminder. ^ Fasten seat belt reminder. ^ Fasten belts indicator control. ^ Parking brake reminder. ^ Turn signal reminder. ^ Low fuel reminder. ^ Headlamps ON reminder. ^ Last door closed locking confirmation. ^ Feature customization. Interior Lighting ^ Interior illumination control. ^ Delayed illumination. ^ Illuminated entry. ^ Exit illumination. ^ Theater dimming. ^ Keyless entry unlock illumination. ^ Inadvertent load (battery rundown) protection. Automatic Door Locks ^ All door unlock. ^ All door lock. ^ Last door closed locking. ^ Lockout prevention. ^ Lockout prevention override. ^ Shift into PARK unlock. ^ Shift out of PARK lock. ^ Remote driver door unlock. ^ Remote all door unlock. ^ Remote all door lock. Keyless Entry ^ Remote driver door unlock. ^ Remote all door unlock. ^ Remote all door lock. ^ Remote activation verification. ^ Remote alarm. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 722 ^ Feature customization of remote activation verification. BCM Wake-Up/Sleep State The BCM performs its functions in the wake-up state. The BCM enters the sleep state when active control or monitoring of system malfunctions has stopped, or when the BCM is idling. The BCM must detect certain wake-up inputs before entering the wake-up state. The BCM monitors its inputs during the sleep state, allowing the BCM to switch between the two states, awake or asleep. The BCM enters the wake-up state when receiving activity on any of these inputs: ^ I/P dimmer switch. ^ Door lock (ajar) switch. ^ Door lock switch. ^ A keyless entry system signal. ^ Inadvertent power (battery rundown) protection transition. ^ The ignition is turned to the LOCK, ACCESSORY or the ON position. The sleep state is when the BCM has stopped active control and monitoring of system functions and has become idle again. For the BCM to enter the wake-up state, the BCM must detect a wake-up condition, mentioned previously. These conditions are called wake-up inputs that cause the BCM to change from a sleep to a wake-up state and begin active control and monitoring. The BCM has the ability to monitor for these wake-up inputs in the sleep state. The BCM enters the sleep state when all of these conditions exist: ^ No activity on the Class 2 serial data link. ^ The ignition switch is in the OFF position. ^ The BCM is not commanding any outputs. ^ No delay timers are actively counting (during theft deterrent re-learn). ^ No wake-up inputs are present. Content Theft (UA6 Option) The Body Control Module features a content theft deterrent system which is designed to defer vehicle vandalism and theft. The content theft deterrent system performs these functions: ^ Flashes the headlamps ^ Sounds the horns ^ Disables fuel delivery to the engine The BCM monitors the following: ^ Status of the doors ^ Lock cylinders ^ Rear compartment lid ^ Power door locks ^ The keyless entry system The BCM operates the headlamps, horns and the theft deterrent indicator, thats in the radio, according to the mode of operation the system is in. The BCM also communicates a fuel enable signal to the Powertrain Control Module (PCM) when the system is armed. Refer to Content Theft Deterrent (CTD) Operation in Theft Deterrent for more information. RPO UA6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Power Requirements The BCM has three main voltage feeds and two grounds. The voltage feed circuits are used to provide power for the BCM's logic, courtesy lights, internal driver operation and the door locks. BCM Inputs The following components provide direct input to the BCM, plus other systems can use this input information in order to carry out certain functions: ^ A/C Request: Provides the BCM with a request signal to command the A/C compressor through the PCM via Class 2 serial data. ^ BCM Ground: Provides ground for BCM operation. ^ BCM Power: Provides voltage for BCM operation. ^ Courtesy Lights On: Provides the driver the ability to request illumination of the vehicle interior. ^ Crank Signal: Determines when the ignition switch is in the start position. ^ Dome Lamp Switch Input: Determines when the dome lamp switch (Headlamp Switch) is closed to request the dome lamp on. ^ Door Lock Switch: Door lock switch request to lock and unlock the vehicle doors. ^ Door Locks: Provides voltage for door lock actuator operation. ^ Door Open: Provides door ajar status. ^ Driver Door Open: Allows certain chime functions when the driver's door is open. ^ DRL Signal Low: This input provides the BCM with Information through an ambient light sensor for the DRL feature. ^ Exterior Lamps Off: Determines when the headlamp switch is in the OFF position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 723 ^ Fog Lamp Switch input: This input provides the BCM with a request for fog lamps through a momentary switch connected to ground. ^ Headlamp Switch Input: Determines when the Headlamp switch is closed to request the headlamps on. ^ High Beam: Determines the status of the headlamp dimmer switch, so the BCM can send the instrument cluster a message, via Class 2, to turn on the high beam indicator. ^ Ignition 0 Signal: Determines when the ignition switch is in ACCESSORY, ON or START position. ^ Ignition 1 Signal: Determines when the ignition switch is in the ON and START positions. ^ Key In Ignition: Determines when the key is fully inserted in the ignition key cylinder. ^ Key Unlock: Determines the status of the door lock cylinder switches for content theft. ^ Lamp Request: This input requests the BCM to energize the Battery Rundown Protection relay after the car has been turned off and all the doors have been closed, so the interior lights can be turned on. ^ Park Brake Applied: Determines when the parking brake is applied. ^ Park Lamp Switch Input: Determines when the park lamp switch (Headlamp Switch) is closed to request the park lamps on. ^ Passlock Sensor Data: Reads the Passlock sensor security code. ^ Rear Compartment Ajar: Determines if the rear decklid is open or closed. ^ Rear Compartment Release: This input requests the BCM to open the rear compartment lid. ^ RFA Link: Provides an interface allowing the transfer of keyless entry information from the Remote Control Door Lock Receiver (RCDLR). ^ Serial Data: provides an interface with the PCM, EBCM, Radio, SDM, DIC and the IPC through the Class 2 serial data link. ^ Surveillance Switch Input: Determines when the surveillance switch is closed to request the surveillance mode. ^ Traction Control Request: This input provides the BCM with a request for Traction Control through a momentary switch connected to ground. BCM Outputs The BCM directly controls these outputs, plus other systems may request the BCM to control these outputs for certain functions: ^ All Door Lock: This output supplies voltage to the door lock actuators when the doors are commanded to lock. This output also supplies ground to all the door lock actuators when the doors are commanded to unlock. ^ Backup Lamp Relay Control: Provides ground to the Backup LP relay control circuit. ^ BTSI Solenoid Control: Provides ground to the Brake Transaxle Shift Interlock Control Solenoid. ^ Door Unlock: This output supplies voltage to the door lock actuators (except the driver door lock actuator) when the doors are commanded to unlock. This output also supplies ground to all the door lock actuators (except the driver door lock actuator) when the doors are commanded to lock. ^ Driver Door Unlock: This output supplies voltage to the driver door lock actuators when the doors are commanded to unlock. This output also supplies ground to the driver door lock actuator when the doors are commanded to lock. ^ DRL Relay Control: Provides ground to the DRL relay control circuit. ^ DRL 5 V Reference: Provides 5 Volts to the ambient light sensor. ^ Inadvertent Load Relay Control Output: Supplies ground to the battery rundown protection relay providing an inadvertent load (battery rundown) protection. ^ Fog Lamp Enable Control: Sends a ground signal to the fog lamp switch when the ignition switch on; this action enables the fog lamp switch. The fog lamps turn on when the fog lamp switch is enabled by the BCM. ^ Headlamp Relay Control: Provides ground to the Headlamp relay control circuit. ^ Horn: Sends a ground signal to the horn relay, sounding the horn for the keyless entry alarm function or the content theft system. ^ Inadvertent Relay Control: Provides ground to the Battery Rundown Protection relay control circuit. ^ Interior Dimming: Controls the voltage to the interior lights dimming system. ^ Load Management Control: Provides voltage to the Rear Defogger relay control circuit and the Heated Seats. ^ Park Lamp Relay Control: Provides ground to the Park Lamp relay control circuit. ^ Passlock Sensor Power: Provides B+ for Passlock sensor operation. ^ Passlock Sensor Ground: Provides ground to the Passlock sensor. ^ RAP Relay Control: Provides voltage to the RAP relay control feed circuit. ^ Rear Compartment Lid Release Output: Provides ground to Rear Compartment Lid Release Actuator. ^ RFA Link: Provides an interface allowing the transfer of keyless entry information to the Remote Control Door Lock Receiver (RCDLR). ^ Serial Data: provides an interface with the PCM, EBCM, Radio, SDM, DIC and the IPC through the Class 2 serial data link. ^ Theater Dimming 1 Control: Supplies ground to activate the Footwell lamps. ^ Theater Dimming 2 Control: Supplies ground to activate the inside rear view mirror lamps, non SEO dome lamp, and the roof rail courtesy/reading lamps. Miscellaneous Functions ^ BRAKE indicator lamp control: The BCM controls the state of the BRAKE indicator lamp based on the status of the parking brake switch by sending a message to the instrument cluster via the Class 2 serial data link. ^ Fog lamp enable control. The BCM controls fog lamp operation, based on the status of the ignition switch. ^ Day/night mode sensing: The BCM determines the ambient light operating mode. The BCM then communicates the information to the Instrument Cluster and Powertrain Control Module (PCM) via the Class 2 serial data link. Passlock Theft Deterrent The Passlock is a vehicle theft deterrent system. The Passlock theft deterrent system contains a Passlock sensor. The Passlock sensor is part of the ignition lock cylinder assembly. The Body Control Module (BCM) provides power and ground to the Passlock sensor. The Passlock sensor interfaces with the BCM through the Passlock detection circuit. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 724 When turning the ignition switch to the start position with the proper key, the Passlock sensor generates an analog voltage signal. This signal is sent through the Passlock detecting circuit. This analog voltage signal is of a specific value to the vehicle, and varies from vehicle to vehicle. When attempting to start the engine, the BCM compares a preset stored analog voltage value with the signal coming from the sensor. Because both values match, the BCM sends a fuel enable password via the Class 2 serial data link to the Powertrain Control Module (PCM). As a result, the PCM enables the crank relay, and allows fuel delivery to the engine. When attempting to start the engine by means other than using the proper key in the ignition switch, the Passlock sensor sends an analog voltage signal of a different value. The BCM compares the preset stored analog voltage value with the signal coming from the sensor. Because both values do not match, the BCM sends a fuel disable password via the Class 2 serial data link to the Powertrain Control Module (PCM). As a result, the PCM disables the crank relay, and does not allow fuel delivery to the engine. Retained Accessory Power (RAP) The Retained Accessory Power (RAP) feature allows the operation of the following functions for 10 minutes (or until a vehicle door opens) after the ignition switch has been turned from the ON or ACCESSORY position to the LOCK position: ^ The radio ^ The power windows ^ The power sunroof (if equipped) Refer to Keyless Entry System Operation in Retained Accessory Power (RAP) for more information. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Body Control Module: Initial Inspection and Diagnostic Overview A Diagnostic Starting Point - Body Control System Begin the diagnosis of the body control system by performing the Diagnostic System Check for the system in which the customer concern is apparent. The Diagnostic System Check will direct you to the correct procedure for diagnosing the system and where the procedure is located. A Diagnostic System Check - Body Control System A Diagnostic System Check-Body Control System TEST DESCRIPTION The number(s) below refer to the step number(s) on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 4. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Code Setting Criteria (Fault) For Device Power Moding Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 727 Body Control Module: Reading and Clearing Diagnostic Trouble Codes With Diagnostic Scan Tool PROCEDURE A Tech II or equivalent Scan tool must be used to retrieve Diagnostic Trouble Codes (DTCs) from the PCM or BCM memory. DTCs can no longer be retrieved at the data link connector. This also eliminates the PCM function of flashing Code 12. Follow the instructions supplied by the Scan tool manufacturer in order to access and read either current and/or history DTCs. Without Diagnostic Scan Tool A Tech II or equivalent scan tool must be used to retrieve Diagnostic Trouble Codes (DTCs) from the PCM memory. DTCs can no longer be retrieved at the data link connector. This also eliminates the PCM function of flashing Code 12. Follow the instructions supplied by the scan tool manufacturer in order to access and read either current and/or history DTCs. With Diagnostic Scan Tool PROCEDURE Use a Tech II or equivalent Scan tool to clear Diagnostic Trouble Codes (DTCs) from the PCM memory. When clearing DTCs, follow the instructions supplied by the Scan tool manufacturer. NOTES: ^ Do not clear the DTCs unless directed to do so by the service information provided for each diagnostic procedure. All of the diagnostic data that was saved along with the DTC (freeze frame data and/or malfunction history records) which may be helpful for some diagnostic procedures will be erased from the memory when the DTCs are cleared. ^ Interrupting PCM battery voltage to clear DTCs is NOT recommended. Without Diagnostic Scan Tool PROCEDURE Use a Tech II or equivalent Scan tool to clear Diagnostic Trouble Codes (DTCs) from the PCM memory. When clearing DTCs, follow the instructions supplied by the Scan tool manufacturer. NOTES: ^ Do not clear the DTCs unless directed to do so by the service information provided for each diagnostic procedure. All of the diagnostic data that was saved along with the DTC (freeze frame data and/or malfunction history records) which may be helpful for some diagnostic procedures will be erased from the memory when the DTCs are cleared. ^ Interrupting PCM battery voltage to clear DTCs is NOT recommended. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 728 Body Control Module: Scan Tool Testing and Procedures Scan Tool Data Definitions Doors Battery Fd: The scan tool displays Inactive/Active. The input of the Doors Battery Fd is displayed as Active. Electronics Battery Fd: The scan tool displays Inactive/Active. The input of the Electronics Battery Fd is displayed as Active. Electronics System Gnd: The scan tool displays Inactive/Active. The input of the Electronics System Gnd is displayed as Active. Ignition 0: The scan tool displays On/Off. The input of the Ignition 0 varies on the scan tool display. Ignition 1: The scan tool displays On/Off. The input of the Ignition 1 varies on the scan tool display. Ignition 3: The scan tool displays On/Off. The input of the Ignition 3 varies on the scan tool display. Inadvert Power Relay: The scan tool displays On/Off. The input of the Inadvert Power Output varies on the scan tool display Loads Battery Fd: The scan tool displays Inactive/Active. The input of the Loads Battery Fd is displayed as Active. Loads System Gnd: The scan tool displays Inactive/Active. The input of the Loads System Gnd is displayed as Active. Theater Dim 1 Ground: The scan tool displays Inactive/Active. The input of the Theater Dim 1 Ground is displayed as Inactive. Theater Dim 2 Ground: The scan tool displays Inactive/Active. The input of the Theater Dim 2 Ground is displayed as Inactive. Scan Tool Data List Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures Body Control Module (BCM) Programming/RPO Configuration INTRODUCTION During body control module (BCM) related service, the procedures below are designated to set-up the BCM correctly. Before you start, read these procedures carefully and completely. SETUP NEW BODY CONTROL MODULE (BCM) IMPORTANT: ^ The BCM will not function properly if the Setup New BCM procedure is not performed. ^ Make sure the battery is fully charged before performing the setup procedure. ^ Make sure all disconnected devices and connectors have been reconnected ^ Perform the Theft Deterrent Re-learn procedure after successfully finishing the Setup New BCM procedure. Refer to Programming Theft Deterrent System Components in Theft Deterrent. If the Theft Deterrent Re-learn procedure is not performed after a BCM replacement, the following conditions may occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank nor start. 1. Connect a scan tool to the data link connector (DLC). 2. Turn the ignition switch ON. 3. Select Diagnostics and input all of the required data when prompted by the scan tool. 4. Select BODY CONTROL MODULE. 5. Select SPECIAL FUNCTIONS. 6. Select Setup New BCM. 7. Note, Input all of the required data when prompted by the scan tool. 8. Select Setup SDM Part Number in BCM, and follow the onscreen directions. 9. Select New VIN, and follow the onscreen directions. 10. Select Option Configuration, and follow the onscreen directions. 11. Select Point of Sale, and follow the onscreen directions. 12. Exit back to the SPECIAL FUNCTIONS menu. 13. When the BCM, VIN, Point of Sale and Option Configuration have been entered, proceed with Theft Deterrent Re-learn procedure. 14. If the scan tool displays UNABLE TO PROGRAM BCM, BCM IS SECURED, then the BCM must be replaced and this procedure must be repeated on a new BCM.. NOTE: After the above procedure has been completed, personalization of the BCM defaults to a default setting. Inform the customer that the personalization settings must be set again. IMPORTANT: After programing, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve History DTCs from all modules. 5. Clear all history DTCs General Information During Body Control Module (BCM) related service, the procedures below are designated to set-up the BCM correctly. Before you start, read these procedures carefully and completely. Theft Deterrent Re-Learn Using T-50 or T-60 1. Enter the T-50 or T-60 Service Programming System (SPS). 2. Select TERMINAL TO VEHICLE PROGRAMMING. 3. Select DONE. 4. Follow the instructions on the VEHICLE SETUP screen. 5. Select THEFT MODULE RE-LEARN. 6. Follow the instructions on the remaining screens. 7. The PCM and BCM will be prepared for re-learn. 8. A security timer will be on for approximately 10 minutes. During the 10 minute wait period, the T-50 or T-60 terminal must remain connected to the vehicle. 9. When the PCM and BCM are prepared to re-learn, turn the ignition switch off. 10. Turn the ignition switch to start. The vehicle should now start. Theft Deterrent Re-Learn W/O Scan Tool Or Techline Equipment This procedure takes approximately 30 minutes. Make sure the battery is fully charged before proceeding. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 731 1. Turn the ignition switch off. 2. Turn the ignition switch all the way from the off to the start position, then leave it in the on position. NOTE: The engine will not crank. 3. The SECURITY will come on and stay on for at least 10 minutes. 4. Turn the ignition switch off for five seconds. 5. Repeat steps 2, 3, and 4 again for a second time. 6. Repeat steps 2, 3, and 4 again for a third time. 7. Turn the ignition switch off. 8. Turn the ignition switch all the way to the start position. The engine should now start. 9. Check for BCM Diagnostic Trouble Codes (DTCs). Theft Deterrent Re-Learn With Techline Equip & Tech 2 Scan Tool 1. Connect the Scan Tool to the Data Link Connector (DLC) on the vehicle. 2. At the Scan Tool main menu, select SERVICE PROGRAMMING. 3. Enter the requested information. 4. Select REQUEST INFO. 5. Disconnect the Scan Tool from the vehicle. 6. Connect the Scan Tool to the Techline terminal. 7. Select SERVICE PROGRAMMING SYSTEM (SPS). 8. Select TERMINAL TO TECH 2 PROGRAMMING. 9. Select DONE. 10. Follow instructions on the Techline terminal to Handheld Communications Setup screen. 11. Select THEFT MODULE RE-LEARN. 12. Select PROGRAM at the summary screen. The terminal will download information to the Scan Tool. 13. Disconnect the Scan Tool from the Techline terminal. 14. Connect the Scan Tool to the DLC on the vehicle. 15. At the Scan Tool main menu, select SERVICE PROGRAMMING. 16. Answer the question prompted by the Scan Tool. 17. Select RE-LEARN. 18. The Powertrain Control Module (PCM) and the BCM will be prepared for re-learn. 19. A security timer will be on for approximately 10 minutes. During the 10 minute wait period, Scan Tool must remain connected to the vehicle. 20. Turn the ignition switch off when the re-learn procedure is complete. 21. Turn the ignition switch to the start position. 22. The engine should start when the ignition switch is turned to the start position. 23. Disconnect the Scan Tool from the DLC. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 732 Body Control Module: Removal and Replacement Body Control Module Replacement REMOVAL PROCEDURE IMPORTANT: You must perform the new body control module (BCM) setup when replacing the BCM. Refer to BCM Programming/RPO Configuration. 1. Disconnect the battery ground (negative) cable. 2. Remove the left instrument panel insulator. 3. Disconnect the BCM electrical connectors (2, 3, 4). 4. Remove the BCM (1). INSTALLATION PROCEDURE 1. Install the body control module (BCM) (1). 2. Connect the BCM electrical connectors (2, 3, 4). 3. Install the left instrument panel insulator 4. Connect the battery ground (negative) cable. 5. Perform the new BCM setup. Refer to BCM Programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Powertrain Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 737 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 738 Powertrain Control Module: Locations Locations View RH side of the engine compartment, forward of the strut tower, inside air box. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 741 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 742 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 743 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 744 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 745 Powertrain Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 746 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 747 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 748 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 749 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 750 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 751 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 752 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 753 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 754 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 755 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 756 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 757 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 758 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 759 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 760 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 761 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 762 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 763 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 764 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 765 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 766 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 767 Powertrain Control Module: Connector Views Powertrain Control Module Connector C1 End View (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 768 Powertrain Control Module Connector C1 End View (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 769 Powertrain Control Module Connector C2 End View (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 770 Powertrain Control Module Connector C2 End View (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > EEPROM Programming Powertrain Control Module: Service and Repair EEPROM Programming 1. The ignition is ON. 2. If the PCM fails to program, inspect the Techline equipment for the latest software version. 3. Attempt to program the PCM. If the PCM still cannot be programmed properly, replace the PCM. The replacement PCM must be programmed. Functional Check 1. Perform A Powertrain On Board Diagnostic (OBD) System Check. 2. Start the engine and let the engine run for one minute. 3. Use the scan tool in order to scan for the DTCs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > EEPROM Programming > Page 773 Powertrain Control Module: Service and Repair PCM Replacement/Programming NOTE: In order to prevent possible Electrostatic Discharge damage to the PCM, Do Not touch the connector pins or the soldered components on the circuit board. Service of the PCM should normally consist of either replacement of the PCM or EEPROM programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if it is the correct part. If it is, remove the faulty PCM and install the new service PCM. NOTE: Turn the ignition OFF when installing or removing the PCM connectors and disconnecting or reconnecting the power to the PCM (battery cable, PCM pigtail, PCM fuse, jumper cables, etc.) in order to prevent internal PCM damage. IMPORTANT: When replacing the production PCM with a service PCM, it is important to transfer the broadcast code and production PCM number to the service PCM label. Do not record on PCM cover. This will allow positive identification of PCM parts throughout the service life of the vehicle. THE SERVICE PCM EEPROM WILL NOT BE PROGRAMMED. DTC P0602 indicates the EEPROM is not programmed or has malfunctioned. Removal Procedure CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Disconnect the IAT sensor electrical connector. 3. Remove the 3 bolts from the inner fender brace and remove the brace. 4. Loosen the clamps securing the air intake duct/MAF sensor to the air cleaner housing and throttle body. 5. Carefully remove the air intake duct/MAF sensor from the throttle body and air cleaner housing (1). 6. Remove the 2 screws (2) from the 2 air cleaner housing sections. 7. Remove the air cleaner housing cover assembly. 8. Without disconnecting the PCM connectors, remove the PCM (4) and harness from the PCM housing (3). 9. Disconnect the PCM connectors. Installation Procedure 1. Connect the PCM connectors. 2. Carefully install the PCM (4) and harness into the PCM housing (3). 3. Install the air cleaner housing cover assembly (1). 4. Install the 2 screws to the 2 air cleaner housing sections. 5. Carefully install the air intake duct to the throttle body and air cleaner housing. 6. Tighten the clamp securing the air intake duct to the air cleaner housing. 7. Position the inner fender brace and reinstall the 3 bolts. 8. Connect the Negative Battery Cable. 9. If a replacement PCM is being installed, program the PCM. The replacement PCM will NOT allow Secondary AIR Pump operation until a total of 10 miles have accumulated. 10. If a replacement PCM is being installed, perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Locations Underhood Fuse Block (Upper) - RH Engine Compartment Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Locations > Page 778 Air Injection Pump Relay: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the underhood electrical center cover. 3. Remove the secondary air pump relay. INSTALLATION PROCEDURE 1. Install the secondary air pump relay. 2. Install the underhood electrical center cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 784 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 785 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 786 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 787 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 788 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 789 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 790 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 791 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 792 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 793 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 794 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 795 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 796 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 797 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 798 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 799 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 800 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 801 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 802 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 803 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 804 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 805 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 806 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 807 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 808 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 809 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 810 Fuel Pump Relay: Service and Repair REMOVAL PROCEDURE 1. Turn the ignition OFF. 2. Remove the under hood electrical center cover. 3. Remove the fuel pump relay. INSTALLATION PROCEDURE 1. Install the fuel pump relay. 2. Install the under hood electrical center cover. 3. Turn the ignition ON. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Specifications Ignition Control Module: Specifications Ignition Coil to Ignition Control Module Screws 4.5 Nm Ignition Controle Module Bracket to Engine Studs and Nuts 25 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Component Locations > Page 817 Ignition Control Module: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Component Locations > Page 818 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Ignition Control Module C1 Ignition Control Module (ICM), C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Ignition Control Module C1 > Page 821 Ignition Control Module (ICM), C2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 822 Ignition Control Module: Description and Operation Ignition Control (IC) Module The Ignition Control (IC) module performs the following functions: ^ It determines the correct ignition coil firing sequence, based on 7X pulses. This coil sequencing occurs at start-up. After the engine is running, the module determines the sequence, and continues triggering the ignition coils in proper sequence. ^ It sends the 3X crankshaft reference (fuel control) signal to the PCM. The PCM determines engine RPM from this signal. this signal is also used by the PCM to determine crankshaft speed for ignition control (IC) spark advance calculations. The 3X reference signal sent to the PCM by the IC module is an on, off pulse occurring 3 times per crankshaft revolution. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 823 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect all the electrical connectors at the ignition control module. 3. Note position of spark plug wires for installation and disconnect the spark plug wires from ignition coils. 4. Remove the screws securing coil assemblies to ignition control module. 5. Disconnect the coils from ignition control module. 6. Remove the fasteners securing ignition control module assembly to engine. 7. Remove the ignition control module from the module mounting bracket. INSTALLATION PROCEDURE 1. Install the ignition control module on the module mounting bracket. 2. Install the coils to ignition control module. 3. Reinstall the screws through the coils and module into the module mounting bracket. NOTE: Refer to Fastener Notice in Service Precautions. 4. Reinstall the screws. Tighten Tighten the screws to 4-5 N.m (40 lb in). 5. Connect the spark plug wires as noted during removal. 6. Connect the electrical connectors to the ignition control module. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Specifications Inflatable Restraint Sensing and Diagnostic Module: Specifications Inflatable Restraint Sensing and Diagnostic Module Fasteners 10 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Diagrams > Inflatable Restraint Sensing and Diagnostic Module (SDM)(C1) Inflatable Restraint Sensing And Diagnostic Module (SDM) (C1) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Diagrams > Inflatable Restraint Sensing and Diagnostic Module (SDM)(C1) > Page 830 Inflatable Restraint Sensing And Diagnostic Module (SDM) (C2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Diagrams > Page 831 Inflatable Restraint Sensing and Diagnostic Module: Service Precautions CAUTION: Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. CAUTION: If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal Injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the Ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Diagrams > Page 832 Inflatable Restraint Sensing and Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE The inflatable restraint Sensing and Diagnostic Module (SDM) performs the following functions in the SIR system: ^ Energy Reserve - The SDM maintains a 23 Volt Loop Reserve (23 VLR) energy supply to provide deployment energy for the air bags. Ignition voltage can provide deployment energy if the 23 Volt Loop Reserves malfunction. ^ Crash Detection Frontal - The SDM monitors vehicle velocity changes in order to detect frontal crashes that are severe enough to warrant deployment. - Side - The SDM monitors vehicle velocity changes along with SIS information in order to detect side impact crashes that are severe enough to warrant deployment. ^ Air Bag Deployment Frontal - During a frontal crash of sufficient force, the SDM will cause enough current to flow through the frontal inflator modules to deploy the frontal air bags. - Side - During a side crash of sufficient force, the SDM will cause enough current to flow through the side impact module to deploy the driver side air bag. ^ Frontal Crash Recording - The SDM records information regarding the SIR system status during a frontal crash. ^ Side Impact System Malfunction Monitoring - The SDM monitors the SIS. The SIS can communicate the status of the side impact air bag system to the SDM. ^ Malfunction Detection - The SDM performs diagnostic monitoring of the SIR system electrical components. Upon detection of a circuit or component malfunction, the SDM will set a DTC. ^ Malfunction Diagnosis - The SDM displays SIR DTCs and system status information through the use of a scan tool. ^ Driver Notification - The SDM notifies the vehicle driver of SIR system malfunctions by controlling the AIR BAG warning lamp in the instrument cluster via Class 2 serial data. The SDM connects to the SIR wiring harness using the following connector(s): ^ The 18-way connector provides power, ground, and all the required interfaces for frontal air bag deployment. ^ The 8-way connector (AJ7) provides all the required interfaces for side impact sensing and side air bag deployment. The SDM receives power whenever the ignition is ON. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) Inflatable Restraint Sensing and Diagnostic Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module (AJ7) CAUTION: Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. CAUTION: If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the passenger front seat. 3. Remove the passenger front carpet retainer, then roll back the carpet. 4. Remove the Connector Position Assurance (CPA) from the inflatable restraint sensing and diagnostic module (SDM) 8-way wiring harness connector. 5. Disconnect the SDM 8-way wiring harness connector from the SDM. 6. Remove the connector position assurance (CPA) from the SDM 18-way wiring harness connector (2). 7. Disconnect the SDM 18-way wiring harness connector from the SDM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 835 8. Remove the SDM mounting fasteners (3). 9. Remove the SDM (1) from the floor pan (2). INSTALLATION PROCEDURE 1. Install the SDM (1) to the floor pan (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the SDM mounting fasteners (3). Tighten Tighten fasteners to 10 N.m (89 lb in). 3. Install the SDM 18-way wiring harness connector to the SDM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 836 4. Install the connector position assurance (CPA) to the SDM 18-way wiring harness connector. 5. Install the SDM 8-way wiring harness connector to the SDM. 6. Install the connector position assurance (CPA) to the SDM 8-way wiring harness connector. 7. Install the carpet and the passenger front carpet retainer. 8. Install the passenger front seat. 9. Enable the SIR system. Refer to Enabling the SIR System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 837 Inflatable Restraint Sensing and Diagnostic Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module (AK5) CAUTION: Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. CAUTION: If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the passenger front seat. 3. Remove the passenger front carpet retainer, then roll back the carpet. 4. Remove the Connector Position Assurance (CPA) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector. 5. Disconnect the SDM wiring harness connector from the SDM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 838 6. Remove the SDM mounting fasteners (3). 7. Remove the SDM (1) from the floor pan (2). INSTALLATION PROCEDURE 1. Install the SDM (1) to the floor pan (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the SDM mounting fasteners (3). Tighten Tighten fasteners to 10 N.m (89 lb in). 3. Install the SDM wiring harness connector to the SDM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 839 4. Install the connector position assurance (CPA) to the SDM wiring harness connector. 5. Install the carpet and the passenger front carpet retainer. 6. Install the passenger front seat. 7. Enable the SIR system. Refer to Enabling the SIR System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations In the RH instrument panel accessory wiring junction block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations Rear Defogger Relay: Locations RH Instrument Panel Fuse Block Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations > Page 853 Locations View In the RH instrument panel Fuse Block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Component Locations Wiper Control Module: Component Locations Locations View LR of the engine compartment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Component Locations > Page 859 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions Wiper Control Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 862 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 863 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 864 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 865 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 866 Wiper Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 867 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 868 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 869 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 870 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 871 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 872 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 873 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 874 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 875 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 876 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 877 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 878 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 879 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 880 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 881 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 882 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 883 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 884 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 885 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 886 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 887 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 888 Windshield Wiper System Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 889 Wiper/Washer System (Pulse) Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 895 Passlock(TM) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Component Locations Power Door Lock Switch: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Component Locations > Page 905 Locations View Center of the front door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Component Locations > Page 906 Power Door Lock Switch: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Component Locations > Page 907 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > LF Door Lock Switch LF Door Lock Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > LF Door Lock Switch > Page 910 RF Door Lock Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures Power Door Lock Switch: Procedures REMOVAL PROCEDURE 1. Remove the inside door handle bezel. 2. Remove the power door lock switch from the inside door handle bezel using a small, flat-bladed tool in order to release the retainers. 3. Disconnect the electrical connector from the power door lock switch. INSTALLATION PROCEDURE 1. Install the power door lock switch to the inside door handle bezel pressing into place until fully seated. 2. Connect the electrical connector to the power door lock switch. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 913 3. Install the inside door handle bezel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 914 Power Door Lock Switch: Removal and Replacement Door Lock Switch Replacement (Impala) Removal Procedure 1. Remove the inside door handle bezel. Refer to Door Inside Handle Bezel Replacement (Impala) (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Door Inside Handle Bezel Replacement). 2. Remove the power door lock switch from the inside door handle bezel using a small, flat-bladed tool in order to release the retainers. 3. Disconnect the electrical connector from the power door lock switch. Installation Procedure 1. Install the power door lock switch to the inside door handle bezel pressing into place until fully seated. 2. Connect the electrical connector to the power door lock switch. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 915 3. Install the inside door handle bezel. Refer to Door Inside Handle Bezel Replacement (Impala) (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Door Inside Handle Bezel Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Outside Rearview Mirror Remote Control Switch Power Mirror Switch: Locations Outside Rearview Mirror Remote Control Switch Front top of the driver's door panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Outside Rearview Mirror Remote Control Switch > Page 920 Power Mirror Switch: Locations Outside Remote Control Rearview Mirror Switch Locations View Front top of the left front door panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 921 Power Mirror Switch: Service and Repair REMOVAL PROCEDURE 1. Remove the front door pull cup from the front door inner trim panel. 2. Disconnect the electrical connectors from the power mirror switch. 3. Remove the power mirror switch from the front door pull cup, using a small flat-bladed tool at the side of the mirror switch in order to release the mirror control switch retainer. 4. Remove the power mirror switch from the front door pull cup. INSTALLATION PROCEDURE 1. Install the power mirror switch to the front door pull cup pressing into place until fully seated. 2. Connect the electrical connectors to the power mirror switch. 3. Install the front door pull cup to the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver Seat Adjuster Switch Driver Seat Adjuster Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver Seat Adjuster Switch > Page 926 Passenger Seat Adjuster Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 927 Power Seat Switch: Service and Repair Power Seat Switch Replacement Removal Procedure 1. Remove the front seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Body and Frame/Seats/Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). 2. Remove the power front seat switch from the front seat outer trim panel, using a small flat bladed tool. 3. Disconnect the electrical connector from the power front seat switch. 4. Remove the power front seat switch from the vehicle. Installation Procedure 1. Connect the electrical connector to the power front seat switch. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 928 2. Install the power front seat switch to the front seat outer trim panel, pressing into place until fully seated. 3. Install the front seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Body and Frame/Seats/Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Heated Seat Switch Seat Heater Switch: Locations Heated Seat Switch On the LH side of the seat. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Heated Seat Switch > Page 933 Seat Heater Switch: Locations Heated Seat Switch, Driver (2-Door) Mounted on the center console. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Heated Seat Switch > Page 934 Seat Heater Switch: Locations Heated Seat Switch, Driver (4-Door) On the LH side of the seat. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Heated Seat Switch > Page 935 Seat Heater Switch: Locations Driver Heated Seat Switch Locations View RPO KA1: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Heated Seat Switch On the LH side of the seat. Heated Seat Switch, Driver (2-Door) Mounted on the center console. Heated Seat Switch, Driver (4-Door) On the LH side of the seat. Heated Seat Switch, Passenger (2-Door) Mounted on the center console. Heated Seat Switch, Passenger (4-Door) On the RH side of the seat. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Heated Seat Switch, Driver Connector Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Heated Seat Switch, Driver Connector > Page 938 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Diagrams > Sunroof Limit Switch, C5 Sunroof Limit Switch, C5 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Diagrams > Sunroof Limit Switch, C5 > Page 944 Sunroof Limit Switch, C4 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Sunroof / Moonroof Switch: Locations Center of the windshield header. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions Sunroof / Moonroof Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 950 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 951 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 952 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 953 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 954 Sunroof / Moonroof Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 955 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 956 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 957 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 958 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 959 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 960 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 961 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 962 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 963 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 964 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 965 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 966 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 967 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 968 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 969 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 970 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 971 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 972 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 973 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 974 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 975 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 976 Sunroof / Moonroof Switch: Electrical Diagrams Power Sunroof Schematics: Without Driver Information Center (DIC) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 977 Power Sunroof Schematics: With Driver Information Center (DIC) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Switch Replacement - Sunroof Position Encoding System Sunroof / Moonroof Switch: Service and Repair Switch Replacement - Sunroof Position Encoding System TOOLS REQUIRED J 41718 Sunroof Timing Pins REMOVAL PROCEDURE IMPORTANT: ^ The sunroof Positioning Encoding Switch (PES) (3) is aligned to the drive cables. The YES switch comes from the factory set to the glass panel CLOSED position. A position lock pin (1) has been installed on the top of the YES switch. The pin (1) must remain until after the installation of the actuator and of the YES switch. The pin locks the drive gears in place and must be removed before operation of the sunroof module. ^ If you reuse a YES switch, place the sunroof glass panel in the CLOSED position. Install the sunroof timing pins J41718. Install a position lock pin, or install 2 wires, such as the ends of a paper clip, then remove the YES switch from the sunroof module. The YES switch timing will be lost if you do not follow this procedure. 1. Position the sunroof glass panel to the closed position. 2. Remove the sunroof module from the vehicle. IMPORTANT: Before removing the YES switch from the sunroof module, the J 41718 sunroof timing pins must be installed to lock the cable/cam mechanism into position. 3. The cable/cam mechanisms on both sides of the glass contain a set of timing holes. These holes are aligned to the sunroof glass panel in the CLOSED position. Remove the left and right side front sunroof glass panel screws. Use a flat-bladed tool to push the cable/cam mechanisms forward or rearward to align with the holes. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Switch Replacement - Sunroof Position Encoding System > Page 980 Install the J41718 sunroof timing pins into the left and right sunroof glass panel screw holes. Install the position lock pin or install 2 wires, such as the ends of a paper clip, to the YES switch before removal of the switch. 4. Remove the sunroof actuator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Switch Replacement - Sunroof Position Encoding System > Page 981 Sunroof / Moonroof Switch: Service and Repair Power Sunroof Switch Replacement (W/O Overhead Console) REMOVAL PROCEDURE 1. Grasp the power sunroof switch on the left and right sides. IMPORTANT: The switch must be rotated, pulled down on the left side, to be removed. 2. Use 2, small, flat-bladed tools in order to disengage the clips which are located at the front and rear of the power sunroof switch. Hold the flat-bladed tools parallel to the roof and push straight in. 3. Rotate the power sunroof switch toward the left side to disengage it from the mounting bracket and pull down. 4. Disconnect the electrical connector from the power sunroof switch. 5. Remove the power sunroof switch from the vehicle. INSTALLATION PROCEDURE 1. Connect the electrical connector to the power sunroof switch. 2. Rotate the power sunroof switch back into the vehicle. 3. Firmly push the power sunroof switch into the headliner until fully seated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Switch Replacement - Sunroof Position Encoding System > Page 982 Sunroof / Moonroof Switch: Service and Repair Power Sunroof Switch Replacement (With Overhead Console) REMOVAL PROCEDURE IMPORTANT: The driver information center control module, and the power sunroof switch is serviced as a complete part. 1. Remove the overhead console. 2. Remove the driver information center control module, containing the power sunroof switch from the overhead console. INSTALLATION PROCEDURE 1. Install the driver information center control module, containing the power sunroof switch to the overhead console. 2. Install the overhead console. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Component Locations Trunk / Liftgate Switch: Component Locations Rear Compartment Lid Ajar Indicator Switch Center of the rear compartment lid. Rear Compartment Lid Release Switch Locations View Left side of the instrument panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Component Locations > Page 987 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 988 Rear Compartment Lid Ajar Indicator Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Rear Compartment Lid Ajar Switch Replacement Trunk / Liftgate Switch: Service and Repair Rear Compartment Lid Ajar Switch Replacement Rear Compartment Lid Ajar Switch Replacement REMOVAL PROCEDURE 1. Open the rear compartment lid. 2. Remove the rear compartment lid latch. Refer to Latch Replacement - Rear Compartment Lid. 3. Remove the rear compartment lid ajar lamp/switch to rear compartment lid latch screw (5). 4. Remove the compartment lid ajar lamp/switch (6) from the rear compartment lid latch (8). INSTALLATION PROCEDURE 1. Position the rear compartment lid ajar lamp/switch (6) to the rear compartment lid latch (8). 2. Install the rear compartment lid ajar lamp/switch to rear compartment lid latch screw (5). Tighten Tighten the rear compartment lid ajar lamp/switch to rear compartment lid latch screw to 5 N.m (44 lb in). 3. Install the rear compartment lid latch. 4. Close the rear compartment lid. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Rear Compartment Lid Ajar Switch Replacement > Page 991 Trunk / Liftgate Switch: Service and Repair Rear Compartment Lid Switch Replacement Rear Compartment Lid Switch Replacement REMOVAL PROCEDURE 1. Release the LH instrument panel (IP) insulator tabs from the lower IP trim pad retainers for access. 2. Remove the LH fuse block access cover. 3. Remove the steering column opening filler panel screws. 4. Release the steering column opening filler panel retainers from the IP lower trim panel. Carefully lower the steering column opening filler panel away from the IP lower trim panel. 5. Disconnect the electrical connector from the rear compartment release switch. 6. Remove the rear compartment release switch. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Rear Compartment Lid Ajar Switch Replacement > Page 992 1. Install the rear compartment release switch. 2. Connect the electrical connector to the rear compartment release switch. 3. Align the steering column opening filler panel to the instrument panel (IP) lower trim panel. Install the steering column opening filler panel retainers to the IP lower trim panel. 4. Install the steering column opening filler panel screws. Tighten Tighten the steering column opening filler panel screws to 2 N.m (18 lb in). 5. Install the LH IP insulator tabs to the lower IP trim pad retainers. 6. Install the LH fuse block access cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 997 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement (With ABS) Removal Procedure 1. Disconnect the electrical connector (2) from the fluid level sensor. 2. Remove the fluid level sensor. Use needle nose pliers in order to compress the switch locking tabs (1) at the side of the master cylinder. Installation Procedure 1. Install the fluid level sensor until the locking tabs snap into place. 2. Connect the electrical connector (2) to the fluid level sensor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Component Locations > Page 1002 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Specifications Parking Brake Warning Switch: Specifications Park Brake Indicator Switch Mounting Screw ..................................................................................................................................................... 26 inch lbs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Specifications > Page 1006 Parking Brake Warning Switch: Service and Repair Removal Procedure 1. Remove the left side instrument panel insulator. Refer to Insulator Replacement - IP (Left) in Instrument Panel, Gauges and Warning Indicators. 2. Remove the left carpet retainer and pull carpet back. Refer to Carpet Retainer Replacement (Impala) or Carpet Retainer Replacement (Monte Carlo) 3. Disconnect the electrical connector from the switch. 4. Remove the mounting screw. 5. Remove the parking brake indicator switch (1). Installation Procedure 1. Install the parking brake indicator switch (1). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the mounting screw. ^ Tighten the mounting screw to 3 Nm (26 inch lbs.). 3. Connect the electrical connector to the switch. Check the operation of the switch. 4. Install the left carpet retainer and carpet. Refer to Carpet Retainer Replacement (Impala) or Carpet Retainer Replacement (Monte Carlo). 5. Install the left side instrument panel insulator. Refer to Insulator Replacement - IP (Left) in Instrument Panel, Gauges and Warning Indicators. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Component Locations Traction Control Switch: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Component Locations > Page 1011 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Component Locations > Page 1012 Traction Control Switch: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Component Locations > Page 1013 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Component Locations > Page 1014 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 1015 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 1016 Traction Control Switch: Service and Repair REMOVAL PROCEDURE 1. Apply the parking brake, if equipped with column shift. 2. Position the transaxle shift control indicator to 1, if equipped with column shift. 3. Adjust the steering wheel for access. 4. Remove the ignition switch cylinder bezel. 5. Remove the LH instrument panel (IP) fuse block access opening cover. 6. Remove the LH P cluster trim plate screws. 7. Start at the left side of the P cluster trim plate. Grasp the trim plate and carefully pull rearward. Disengage enough IP cluster trim plate retainers in order to easily access the traction control switch. 8. Disconnect the electrical connectors from the traction control switch. 9. Remove the traction control switch from the IP cluster trim plate. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 1017 1. Install the traction control switch to the IP cluster trim plate. 2. Connect the electrical connector to the traction control switch. 3. Carefully press the IP cluster trim plate into the IP trim pad. Make sure all of the retainers are fully engaged. 4. Install the LH IP cluster trim plate screws. Tighten Tighten the IF cluster trim plate screws to 2 N.m (18 lb in). 5. Install the LH instrument panel (IP) fuse block access opening covers. 6. Install the ignition switch cylinder bezel. 7. Return the steering wheel to the original position. 8. Position the transaxle shift control indicator to Park, if equipped with a column shift. 9. Push to release the parking brake, if equipped with column shift. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > LF Wheel Speed Sensor Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > LF Wheel Speed Sensor > Page 1022 Wheel Speed Sensor: Locations Wheel Speed Sensor, Rear In the rear wheel hub(s). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, LF Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, LF > Page 1025 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, LF > Page 1026 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, LF > Page 1027 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (Front) Removal Procedure Important: The front wheel speed sensors and rings are integral with the hub and bearing assemblies. If a speed sensor or a ring needs replacement, replace the entire hub and bearing assembly. Do not service the harness pigtail individually because the harness pigtail is part of the sensor. Refer to Front Wheel Drive Shaft Bearing Replacement. 1. Raise and support the vehicle on a suitable hoist. Refer to Vehicle Lifting. 2. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation. 3. Remove the front wheel speed sensor jumper harness electrical connector (1) from the front wheel speed sensor connector (3). 4. Remove the hub and bearing assembly (2). Refer to Front Wheel Drive Shaft Bearing Replacement for removal. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) > Page 1030 1. Install the hub and bearing assembly (2) to the vehicle. Refer to Front Wheel Drive Shaft Bearing Replacement for installation. 2. Install the front wheel speed sensor jumper harness electrical connector (1) to front wheel speed sensor connector (3). 3. Install the wheel and tire assembly. Refer to Tire and Wheel Removal and Installation. 4. Lower the vehicle. 5. Turn the ignition switch to the RUN position with the engine off. 6. Perform the A Diagnostic System Check - ABS. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) > Page 1031 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (Rear) Removal Procedure Important: The rear wheel speed sensors and rings are integral with the hub and bearing assemblies. If a speed sensor or a ring needs replacement, replace the entire hub and bearing assembly. Refer to Wheel Bearing/Hub Replacement - Rear. 1. Raise and support the vehicle on a suitable hoist. Refer to Vehicle Lifting. 2. Remove the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation. 3. Remove the rear wheel speed sensor electrical connector (1) located next to the rear strut (2). 4. Remove the hub and bearing assembly (1). Refer to Wheel Bearing/Hub Replacement - Rear for removal. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) > Page 1032 1. Install the hub and bearing assembly (1) to the vehicle. Refer to Wheel Bearing/Hub Replacement - Rear for installation. 2. Install the rear wheel speed sensor electrical connector (1). 3. Install the wheel and tire assembly. Refer to Tire and Wheel Removal and Installation. 4. Lower the vehicle. 5. Turn the ignition switch to the RUN position with the engine off. 6. Perform the A Diagnostic System Check ABS. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Customer Interest for Coolant Level Sensor: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON Coolant Level Sensor: Customer Interest Instruments - Low Coolant Indicator Always ON Bulletin No.: 04-06-02-007 Date: August 11, 2004 TECHNICAL Subject: Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination) Models: 2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue Condition Some customers may comment that the low engine coolant level indicator is always illuminated. Cause The cause of this condition may be due to engine oil contaminating the coolant. Possible sources of oil contamination are internal engine leaks, improper service procedures, or the addition of some types of anti-leak additives to the cooling system. Once in the coolant, the oil leaves deposits on the level sensor creating an insulating film. This film results in a false activation of the coolant level indicator. Correction Diagnose low coolant level system operation and check the sensor for oil contamination using the procedure listed below. Important: No coolant supplements should be used in GM cooling systems, other than what is approved and recommended by GM. The use of "aftermarket" over-the-counter sealing and cooling supplements may affect the operation of the low coolant level sensor. Discoloration of the coolant recovery bottle is normal and does not necessarily indicate that coolant contamination is present. Flush cooling system only when instructed by this bulletin. 1. Verify that the coolant is at proper level in the radiator and the coolant recovery bottle. If the coolant is low, add proper amount of 50/50 water and DEX-COOL(R) mixture. If the low coolant light operates properly, diagnose the cooling system for loss of coolant as outlined in SI. DO NOT proceed further with this bulletin. 2. Remove the low coolant level sensor. Refer to Coolant Level Module Replacement in the Engine Cooling sub-section. 3. With the key on, the engine off and the coolant level sensor disconnected from the vehicle wiring harness, observe the low coolant light: ^ Light is on - Chassis wiring or instrument cluster concern. Follow the appropriate diagnostic information in SI. ^ Light is out - Proceed to Step 4. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Customer Interest for Coolant Level Sensor: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON > Page 1042 4. With the key off, connect the coolant level sensor into the vehicle's wiring harness. Connect a ground wire (1) to the battery negative terminal. Using a sharp probe (3) attached to the ground wire, ground the coolant sensor probe (2) as shown in the illustration. Make sure a good contact is made. With the key on and the engine off, observe the low coolant light for at least 15 seconds. ^ Light is on - Replace the low coolant sensor and re-check system operation. ^ Light is out - Proceed to Step 5. 5. Using a small wire brush or emery cloth, polish the low coolant level sensor probe to remove any film or oxidation. The probe should be a bright brass color when finished. Use Brake Parts Cleaner to flush removed deposits from the low coolant sensor probe. Re-install the low coolant sensor into the vehicle and proceed to Step 6. 6. Flush the cooling system and install new DEX-COOL(R) mixture as outlined in the SI. Check the vehicle's warranty history to determine if any engine gasket had recently been changed. If there has not been a recent gasket replacement, locate and repair the source of the engine oil contamination. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Customer Interest for Coolant Level Sensor: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON > Page 1043 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Level Sensor: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON Coolant Level Sensor: All Technical Service Bulletins Instruments - Low Coolant Indicator Always ON Bulletin No.: 04-06-02-007 Date: August 11, 2004 TECHNICAL Subject: Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination) Models: 2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue Condition Some customers may comment that the low engine coolant level indicator is always illuminated. Cause The cause of this condition may be due to engine oil contaminating the coolant. Possible sources of oil contamination are internal engine leaks, improper service procedures, or the addition of some types of anti-leak additives to the cooling system. Once in the coolant, the oil leaves deposits on the level sensor creating an insulating film. This film results in a false activation of the coolant level indicator. Correction Diagnose low coolant level system operation and check the sensor for oil contamination using the procedure listed below. Important: No coolant supplements should be used in GM cooling systems, other than what is approved and recommended by GM. The use of "aftermarket" over-the-counter sealing and cooling supplements may affect the operation of the low coolant level sensor. Discoloration of the coolant recovery bottle is normal and does not necessarily indicate that coolant contamination is present. Flush cooling system only when instructed by this bulletin. 1. Verify that the coolant is at proper level in the radiator and the coolant recovery bottle. If the coolant is low, add proper amount of 50/50 water and DEX-COOL(R) mixture. If the low coolant light operates properly, diagnose the cooling system for loss of coolant as outlined in SI. DO NOT proceed further with this bulletin. 2. Remove the low coolant level sensor. Refer to Coolant Level Module Replacement in the Engine Cooling sub-section. 3. With the key on, the engine off and the coolant level sensor disconnected from the vehicle wiring harness, observe the low coolant light: ^ Light is on - Chassis wiring or instrument cluster concern. Follow the appropriate diagnostic information in SI. ^ Light is out - Proceed to Step 4. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Level Sensor: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON > Page 1049 4. With the key off, connect the coolant level sensor into the vehicle's wiring harness. Connect a ground wire (1) to the battery negative terminal. Using a sharp probe (3) attached to the ground wire, ground the coolant sensor probe (2) as shown in the illustration. Make sure a good contact is made. With the key on and the engine off, observe the low coolant light for at least 15 seconds. ^ Light is on - Replace the low coolant sensor and re-check system operation. ^ Light is out - Proceed to Step 5. 5. Using a small wire brush or emery cloth, polish the low coolant level sensor probe to remove any film or oxidation. The probe should be a bright brass color when finished. Use Brake Parts Cleaner to flush removed deposits from the low coolant sensor probe. Re-install the low coolant sensor into the vehicle and proceed to Step 6. 6. Flush the cooling system and install new DEX-COOL(R) mixture as outlined in the SI. Check the vehicle's warranty history to determine if any engine gasket had recently been changed. If there has not been a recent gasket replacement, locate and repair the source of the engine oil contamination. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Level Sensor: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON > Page 1050 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor 23 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1055 Coolant Temperature Sensor/Switch (For Computer): Locations LH side, top of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1058 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1059 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1060 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1061 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1062 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1063 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1064 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1065 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1066 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1067 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1068 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1069 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1070 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1071 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1072 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1073 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1074 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1075 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1076 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1077 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1078 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1079 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1080 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1081 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1082 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1083 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1084 Engine Coolant Temperature (ECT) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1085 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 1086 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The engine coolant temperature sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance (100,000 ohms at -40°C/-40°F) while high temperature causes low resistance (70 ohms at 130° C/266° F). The PCM supplies a 5.0 volt signal to the engine coolant temperature sensor through a resistor in the PCM and measures the voltage. The voltage will be high when the engine is cold, and low when the engine is hot. By measuring the voltage, the PCM calculates the engine coolant temperature. Engine coolant temperature affects most systems the PCM controls. The scan tool displays engine coolant temperature in degrees. After engine startup, the temperature should rise steadily to about 90°C (194°F) then stabilize when thermostat opens. If the engine has not been run for several hours (overnight), the engine coolant temperature and intake air temperature displays should be close to each other. A hard fault in the engine coolant sensor circuit should set DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage, or DTC P0118 Engine Coolant Temperature (ECT) Sensor Circuit High Voltage, an intermittent fault should set a DTC P1114 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent Low Voltage, or DTC P1115 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent High Voltage. The DTC Diagnostic Aids also contains a chart to test for sensor resistance values relative to temperature. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 1087 The ECT sensor (3) also contains another circuit which is used to operate the engine coolant temperature gauge located in the instrument panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 1088 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Relieve coolant pressure. 3. Disconnect the ECT sensor electrical connector. 4. Using a deep well socket and extension, remove the sensor. INSTALLATION PROCEDURE 1. Coat the engine coolant temperature sensor threads with sealer P/N 9985253 or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the sensor in the engine. Tighten Tighten the sensor to 23 N.m (17 lb ft). 3. Connect the ECT sensor electrical connector. 4. Start the engine. 5. Inspect for leaks. 6. Inspect the coolant level. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation Brake Switch (Cruise Control): Description and Operation The cruise control release switch and the stop lamp switch disengage the cruise control system. A cruise control release switch and a stop lamp switch are mounted on the brake pedal bracket. The switches disengage the system electrically when the brake pedal is pressed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations Cruise Control Switch: Component Locations Cruise Control ON/OFF Switch On the turn signal lever. On the steering wheel spoke. Cruise Control Release Switch Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations > Page 1097 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations > Page 1098 Locations View Behind the LH side of the instrument panel, on the brake pedal support. Cruise Control Resume/Accel Switch On the steering wheel spoke. Cruise Control Set/Cancel Switch On the steering wheel spoke. Cruise Control Steering Wheel Switch (LH) (SET/COAST) Lower Left side of steering wheel. Cruise Control Steering Wheel Switch (RH) (RESUME/ACCEL) Lower right side of steering wheel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations > Page 1099 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations > Page 1100 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations > Page 1101 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations > Page 1102 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions Cruise Control Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1105 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1106 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1107 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1108 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1109 Cruise Control Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1110 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1111 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1112 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1113 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1114 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1115 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1116 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1117 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1118 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1119 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1120 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1121 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1122 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1123 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1124 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1125 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1126 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1127 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1128 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1129 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1130 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1131 Cruise Control Release Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1132 Cruise Control Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Cruise Release Switch Replacement Cruise Control Switch: Service and Repair Cruise Release Switch Replacement REMOVAL PROCEDURE CAUTION: ^ Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components. ^ This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions: ^ Air bag deployment ^ Personal injury ^ Unnecessary SIR system repairs In order to avoid the above conditions, observe the following guidelines: ^ Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring. ^ If you are performing service on or near the SIR components or the SIR wiring, disable the SIR system. Refer to Disabling the SIR System in SIR. 1. Remove the driver side knee bolster panel. 2. Remove the electrical connector from the cruise control release switch. 3. Remove the cruise control release switch from the retainer in the brake pedal bracket. INSTALLATION PROCEDURE 1. Install the cruise control release switch to the retainer in the brake pedal bracket. 2. Install the electrical connector onto the cruise control release switch. 3. Adjust the cruise control release switch. 4. Install the driver side knee bolster panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Cruise Release Switch Replacement > Page 1135 Cruise Control Switch: Service and Repair Cruise Release Switch Adjustment IMPORTANT: The cruise control release switch and the stop lamp switch are adjusted together. Incorrect adjustment of either of these switches may cause premature brake lining wear or the cruise control system to not work properly. 1. Remove the left side insulator panel. 2. Press the brake pedal fully. 3. Push the switches into the retainers until the switches are fully seated. 4. Pull the brake pedal rearward against the pedal stop until the audible clicks can no longer be heard. 5. The following brake pedal travel distances can be used to validate the proper cruise control release switch and stop lamp switch adjustment. Cruise control release switch and the stop lamp switch contacts must actuate at 3.5 to 12.5 mm (1/8 to 1/2 in) of the brake pedal travel measured at the centerline of the brake pedal pad. Nominal actuation of the stop lamp switch contacts is about 4.5 mm (3/16 in) after the cruse control release switch actuation. 6. Install the left side insulator panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Specifications Oil Level Sensor: Specifications Oil Level Sensor Bolt 89 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Specifications > Page 1140 Oil Level Sensor: Locations Locations View Front center of the engine oil pan. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Locations Oil Level Sensor For ECM: Locations Front center of the engine oil pan. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Locations > Page 1144 Engine Oil Level Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Engine Oil Pressure Indicator Switch 115 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 1148 Engine Oil Pressure Indicator Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 1152 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Component Locations Oil Pressure Switch (For Fuel Pump): Component Locations Engine Oil Pressure Indicator Switch (LA1) Front of the engine, above the starter. RPO LA1: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Engine Oil Pressure Indicator Switch (L36) Near generator. RPO L36: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Component Locations > Page 1157 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Component Locations > Page 1158 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 1159 Oil Pressure Switch (For Fuel Pump): Description and Operation Engine Oil Pressure Switch The PCM monitors the engine oil pressure switch (1) signal to determine if the engine oil pressure is OK. If the PCM determines that a low oil pressure condition exists, the PCM will communicate the information over the Class II circuit to the P cluster and it will illuminate the indicator lamp or initiate a message. The low oil pressure message may not appear if other messages are being commanded, such as the rear deck lid, driver or passenger doors ajar. Ensure that all doors and compartment lids are completely closed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Component Locations > Page 1165 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1166 Ambient Outside Air Temperature Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1167 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Temperature Sensor Replacement REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. 3. Disconnect the electrical connector from the ambient temperature sensor that is located on the front radiator air baffle. 4. Remove the ambient temperature sensor from the radiator air baffle. INSTALLATION PROCEDURE 1. Install the ambient temperature sensor to the radiator air baffle. 2. Connect the electrical connector to the ambient temperature sensor. 3. Lower the vehicle. 4. Connect the negative battery cable. 5. Drive the vehicle at a speed of 32 km/h (20 mph) for approximately one and a half minutes or at a speed of 72 km/h (45 mph) for approximately one minute in order to obtain the ambient update. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications Refrigerant Pressure Sensor / Switch: Specifications A/C Refrigerant Pressure Sensor 4.7 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Component Locations > Page 1173 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1174 A/C Refrigerant Pressure Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1175 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Refrigerant Pressure Sensor The A/C refrigerant pressure sensor signal indicates high side refrigerant pressure to the PCM. The PCM uses this information to adjust the idle air control valve to compensate for the higher engine loads present with high A/C refrigerant pressures and to control the cooling fans. A fault in the A/C refrigerant pressure sensor signal will cause DTC P0530 Air Conditioning (A/C) Refrigerant Pressure Sensor Circuit to set. When A/C is selected the PCM increases the engine idle speed just prior to A/C clutch engagement for better idle quality. In addition the PCM will command the cooling fans on during A/C operation. The PCM monitors the A/C refrigerant pressure. If the A/C refrigerant pressure, and engine operating conditions are within a specific calibrated acceptable ranges the PCM will enable the A/C compressor relay. This is accomplished by providing a ground path for the A/C relay coil within the PCM. When the A/C compressor relay is enabled battery voltage is supplied to the compressor clutch coil. The PCM will enable the A/C compressor clutch whenever the engine is running and the A/C has been requested, unless any of the following conditions are met: ^ Throttle more than 90 percent ^ A/C head pressure more than 427 psi (4.27 volts) or less than 41 psi (0.35 volt) (as determined by the A/C refrigerant pressure sensor). ^ Ignition voltage below 9.5 volts. ^ Engine speed more than 6900 RPM for 5 seconds. ^ ECT more than 121°C (250°F). ^ IAT less than °C (32°F). For more information regarding the A/C System, refer to HVAC Compressor Controls Circuit Description in Heating and Air Conditioning. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1176 Refrigerant Pressure Sensor / Switch: Service and Repair A/C REFRIGERANT PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. 2. Remove the air cleaner and duct assembly. 3. Disconnect the electrical connector (2) from the A/C refrigerant pressure sensor. 4. Remove the A/C refrigerant pressure sensor (1) from the liquid line. INSTALLATION PROCEDURE 1. Lubricate a new O-ring seal with mineral base 525 viscosity refrigerant oil. 2. Install the new O-ring seal. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the A/C refrigerant pressure sensor (1) to the liquid line. Tighten Tighten the A/C refrigerant pressure sensor to 4.7 N.m (41 lb in). 4. Connect the electrical connector (2) to the A/C refrigerant pressure sensor. 5. Install the air cleaner and duct assembly. 6. Connect the battery negative cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Technical Service Bulletins > IP Dimmer Control - Proper Setting Dimmer Switch: Technical Service Bulletins IP Dimmer Control - Proper Setting File In Section: 08 - Body and Accessories Bulletin No.: 99-08-42-009 Date: November, 1999 INFORMATION Subject: Proper Setting of I/P Dimmer Control to View PRNDL Display with Automatic Headlamp Control Models: 2000 and Prior All Passenger Cars and Trucks With Automatic Headlamp Control and Electronic PRNDL Display Under certain conditions, if the instrument panel dimmer control is turned relatively low, the PRNDL will not be visible until the automatic headlamp control turns the headlamps off and the daytime running lamps (DRL) are turned back on. Such a condition may be if the vehicle is first started in an environment where the headlamp control turns on the headlamps and then the vehicle is driven out into a brighter environment (for example, when a vehicle is backed out of a dark garage into the bright sunlight). This condition is normal and any repair attempt will not be successful. Demonstrate this condition to the customer using the service lane and then turn the instrument panel dimmer control to a higher setting. This will enable the driver to see the PRNDL display Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Technical Service Bulletins > Page 1182 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Mounted in the fuel tank. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1188 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1189 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1190 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1191 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1192 Fuel Gauge Sender: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1193 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1194 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1195 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1196 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1197 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1198 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1199 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1200 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1201 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1202 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1203 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1204 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1205 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1206 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1207 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1208 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1209 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1210 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1211 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1212 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1213 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1214 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 1215 Fuel Gauge Sender: Description and Operation The fuel level sensor consists of the following components: float, the wire float arm, and the ceramic resistor card. The fuel level sensor is mounted on the modular fuel sender assembly and is used as an input to the PCM. The PCM uses this information as a fuel level input for Various diagnostics. In addition the PCM transmits the fuel level over the Class II communication circuit to the IP cluster. This information is used for the IP fuel gauge, and low fuel warning indicator if applicable. Fuel Level Sensor The Fuel Level Sensor(4) is mounted on the Modular Fuel Sender Assembly(s). The PCM uses the fuel level input for various diagnosis including the EVAP System. In addition the PCM transmits the fuel level over the Class II communication circuit to the IP Cluster. The low fuel level message may not appear if other messages are being commanded, such as the rear deck lid, driver or passenger doors ajar. Ensure that all doors and compartment lids are completely closed. For further information regarding the Fuel Level Sensor refer to Fuel Metering Modes of Operation. See: Powertrain Management/Fuel Delivery and Air Induction/Description and Operation/Fuel Metering/Fuel Metering Modes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 1216 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure. See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 2. Remove the modular fuel sender assembly. 3. Remove the fuel level sensor (5) from the modular fuel sender. INSTALLATION PROCEDURE 1. Reinstall the fuel level sensor (5) to modular fuel sender. 2. Reinstall the fuel sender assembly. 3. Tighten the fuel filler cap. 4. Reconnect the negative battery cable. 5. Inspect for fuel leaks. 5.1. Turn the ignition ON for 2 seconds 5.2. Turn the ignition OFF for 10 seconds. 5.3. Turn the ignition ON. 5.4. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Specifications Parking Brake Warning Switch: Specifications Park Brake Indicator Switch Mounting Screw ..................................................................................................................................................... 26 inch lbs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Specifications > Page 1220 Parking Brake Warning Switch: Service and Repair Removal Procedure 1. Remove the left side instrument panel insulator. Refer to Insulator Replacement - IP (Left) in Instrument Panel, Gauges and Warning Indicators. 2. Remove the left carpet retainer and pull carpet back. Refer to Carpet Retainer Replacement (Impala) or Carpet Retainer Replacement (Monte Carlo) 3. Disconnect the electrical connector from the switch. 4. Remove the mounting screw. 5. Remove the parking brake indicator switch (1). Installation Procedure 1. Install the parking brake indicator switch (1). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the mounting screw. ^ Tighten the mounting screw to 3 Nm (26 inch lbs.). 3. Connect the electrical connector to the switch. Check the operation of the switch. 4. Install the left carpet retainer and carpet. Refer to Carpet Retainer Replacement (Impala) or Carpet Retainer Replacement (Monte Carlo). 5. Install the left side instrument panel insulator. Refer to Insulator Replacement - IP (Left) in Instrument Panel, Gauges and Warning Indicators. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions Ambient Light Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1226 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1227 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1228 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1229 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1230 Ambient Light Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1231 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1232 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1233 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1234 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1235 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1236 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1237 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1238 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1239 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1240 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1241 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1242 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1243 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1244 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1245 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1246 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1247 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1248 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1249 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1250 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1251 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1252 DRL Ambient Light Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 1253 Ambient Light Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the defroster grille. 2. Remove the daytime running lamp ambient light sensor socket from the defroster grille by twisting 1/4 turn counterclockwise. 3. Remove the daytime running lamp ambient light sensor from the daytime running lamp ambient light connector. INSTALLATION PROCEDURE 1. Install the daytime running lamp ambient light sensor to the daytime running lamp ambient light sensor socket. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 1254 2. Install the daytime running lamp ambient light sensor socket to the defroster grille twisting 1/4 turn clockwise. 3. Install the instrument panel upper trim pad. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Stop Lamp Switch, C1 Stop Lamp Switch, C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Stop Lamp Switch, C1 > Page 1260 Stop Lamp Switch, C2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 1261 Brake Light Switch: Adjustments Notice: Proper stoplamp switch adjustment is essential. Improper stoplamp switch adjustment may cause brake drag, heat buildup and excessive brake lining wear. Important: Adjust the stoplamp switch and the cruise control switch (If equipped). at the same time. The adjustment procedure for both switches is identical. Refer to Cruise Release Switch Adjustment in order to adjust the cruise control release switch. With the brake pedal in the fully released position, ensure that the stoplamp plunger is fully depressed against the brake pedal shanks. 1. Insert the stoplamp switch and the cruise control switch (if equipped) into the brake pedal bracket. 2. Push the brake pedal forward in order to set the brake push rod into the booster. 3. Pull the brake pedal to the rear, against the internal stop. This adjusts both the stoplamp switch and the cruise control switch. 4. Inspect the stoplamp switch for proper adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 1262 Brake Light Switch: Service and Repair Removal Procedure 1. Remove the driver's side instrument panel insulator. Refer to Insulator Replacement - IP (Left) or Insulator Replacement - IP (Right) in Instrument Panel, Gauges and Warning Indicators. 2. Disconnect the electrical connectors. 3. Remove the stoplamp switch (2) from the brake pedal bracket. Installation Procedure 1. Install the stoplamp switch (2) to the brake pedal bracket. 2. Connect the electrical connectors. 3. Adjust the stoplamp switch. Refer to Stoplamp Switch Adjustment. 4. Install the driver's side instrument panel insulator. Refer to Insulator Replacement - IP (Left) or Insulator Replacement - IP (Right) in Instrument Panel, Gauges and Warning Indicators. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Component Locations Fog/Driving Lamp Switch: Component Locations Locations View In the LH side of instrument panel, next to the headlamp switch. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Component Locations > Page 1267 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Fog/Driving Lamp Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1270 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1271 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1272 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1273 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1274 Fog/Driving Lamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1275 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1276 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1277 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1278 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1279 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1280 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1281 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1282 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1283 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1284 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1285 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1286 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1287 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1288 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1289 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1290 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1291 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1292 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1293 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1294 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1295 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1296 Fog Lamp Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1297 Fog Lights Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Page 1298 Fog/Driving Lamp Switch: Service and Repair REMOVAL PROCEDURE 1. Remove the instrument panel cluster trim plate bezel. 2. Remove the screws from the headlamp switch housing. 3. Remove the headlamp switch housing from the instrument panel. 4. Disconnect the electrical connector from the headlamp switch. 5. Remove the headlamp switch from the headlamp switch housing. INSTALLATION PROCEDURE 1. Install the headlamp switch to the headlamp switch housing, pressing into place until fully seated. 2. Connect the electrical connector to the headlamp switch. 3. Install the headlamp switch housing to the instrument panel. 4. Install the headlamp switch housing screws. Tighten Tighten the headlamp housing switch screws to 2 Nm (18 lb in). 5. Install the instrument panel cluster trim plate bezel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Locations > Component Locations > Page 1303 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Component Locations > Page 1308 Hazard Warning Switch: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Component Locations > Page 1309 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 1310 Hazard Warning Switch: Service and Repair REMOVAL PROCEDURE 1. Apply the parking brake. 2. Position the transaxle shift control indicator to 1, if equipped with column shift. 3. Adjust the steering wheel for access. 4. Remove the ignition switch cylinder bezel. 5. Remove the RH and LH instrument panel (IP) fuse block access opening covers. (Impala Only) 6. Remove the LH instrument panel (IP) fuse block access opening cover. (Monte Carlo Only) 7. Remove the steering column filler. 8. Open the instrument panel compartment door. (Monte Carlo Only) 9. Remove the IP cluster trim plate screws. 10. Start at the left side of the IP cluster trim plate. Grasp the trim plate and carefully pull rearward. Disengage the IP cluster trim plate in order to easily access the hazard warning switch. 11. Disconnect the electrical connectors from the hazard warning switch. 12. Remove the hazard warning switch from the IP cluster trim plate. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 1311 INSTALLATION PROCEDURE 1. Install the hazard warning switch to the IP cluster trim plate. 2. Connect the electrical connector to the hazard warning switch. 3. Press the IP cluster trim plate into the IP trim pad, until all of the retainers are fully seated. 4. Install the IP cluster trim plate screws. Tighten Tighten the IP cluster trim plate screws to 2 N.m (18 lb in). 5. Install the LH instrument panel (IP) fuse block access opening cover. (Monte Carlo Only) 6. Install the steering column filler. 7. Close the instrument panel compartment door. (Monte Carlo Only) 8. Install the ignition switch cylinder bezel. 9. Reposition the steering wheel to the original position. 10. Position the transaxle shift control indicator to Park, if equipped with column shift. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 1312 11. Release the parking brake. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Component Locations Headlamp Switch: Component Locations Locations View Headlamp Switch Location LH side of the instrument panel, to the left of the steering column. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Component Locations > Page 1320 Headlamp Switch: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Component Locations > Page 1321 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1324 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1325 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1326 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1327 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1328 Headlamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1329 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1330 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1331 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1332 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1333 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1334 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1335 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1336 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1337 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1338 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1339 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1340 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1341 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1342 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1343 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1344 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1345 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1346 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1347 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1348 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1349 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1350 Headlamp Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 1351 Headlamp Switch: Service and Repair REMOVAL PROCEDURE 1. Remove the instrument panel cluster trim plate bezel. 2. Remove the screws from the headlamp switch housing. 3. Remove the headlamp switch housing from the instrument panel. 4. Disconnect the electrical connector from the headlamp switch. 5. Disconnect the electrical connector from the foglamp switch. 6. Remove the foglamp switch from the headlamp switch housing, using a small flat bladed tool. INSTALLATION PROCEDURE 1. Install the foglamp switch to the headlamp switch housing, pressing into place until fully seated. 2. Connect the electrical connector to the headlamp switch. 3. Connect the electrical connector to the foglamp switch. 4. Install the headlamp housing switch to the instrument panel. 5. Install the screws to the headlamp housing switch. Tighten Tighten the headlamp housing switch screws to 2 Nm (18 lb in). 6. Install the instrument panel cluster trim plate bezel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Horn Switch Location Horn Switch: Locations Horn Switch Location Behind the steering wheel inflator module. In the steering wheel inflator module. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Horn Switch Location > Page 1356 Horn Switch: Locations Horn Switch Spring Loaded Contact Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Horn Switch Location > Page 1357 Locations View Behind the steering wheel inflator module. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Hazard Lamp/Turn Signal Lamp Flasher Switch Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Hazard Lamp/Turn Signal Lamp Flasher Switch > Page 1362 Turn Signal Switch: Locations Multifunction Lever Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Hazard Lamp/Turn Signal Lamp Flasher Switch > Page 1363 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Hazard Lamp/Turn Signal Lamp Flasher Switch > Page 1364 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Hazard Lamp/Turn Signal Lamp Flasher Switch > Page 1365 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Hazard Lamp/Turn Signal Lamp Flasher Switch > Page 1366 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1369 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1370 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1371 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1372 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1373 Turn Signal Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1374 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1375 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1376 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1377 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1378 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1379 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1380 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1381 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1382 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1383 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1384 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1385 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1386 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1387 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1388 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1389 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1390 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1391 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1392 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1393 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1394 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1395 Turn Signal Switch: Service and Repair Removal Procedure 1. Verify that the multifunction turn signal lever is in the center of the OFF position. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging 3. Disable the SIR system. Refer to Disabling the SIR System in Air Bags and Seat Belts. 4. Remove the steering wheel. Refer to Steering Wheel Replacement. 5. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement - On Vehicle. 6. Remove the steering column wire harness (1) from the steering column wire harness retainer (2). 7. Remove the two wire harness straps from the steering column wire harness (1). 8. Remove the steering column bulkhead connector from the vehicle wire harness. 9. Disconnect the connectors from the multifunction turn signal lever steering column bulkhead connector. 10. Remove the retaining bolts (1) from the multifunction turn signal lever (2). 11. Remove the multifunction turn signal lever (2) from the steering column. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1396 1. Install the multifunction turn signal lever (2). Use a small flat-blade in order to compress the electrical contact and move the multifunction turn signal lever into position. 2. Verify that the electrical contact rests on the canceling cam. Notice: Refer to Fastener Notice in Service Precautions 3. Install the retaining bolts to the multifunction turn signal lever. Tighten the retaining bolts to 7 Nm (62 inch lbs.). 4. Connect the gray and black connectors to the multifunction turn signal lever steering column bulkhead connector. 5. Connect the steering column bulkhead connector to the vehicle wire harness. 6. Install the two wire harness straps to the steering column wire harness (1). 7. Install the steering column wire harness (1) to the steering column wire harness retainer (2). 8. Install the steering column trim cover. Refer to Steering Column Trim Cover Replacement - On Vehicle. 9. Verify that the lever is in the center or the OFF position. 10. Install the steering wheel to the steering column. Refer to Steering Wheel Replacement 11. Enable the SIR system. Refer to Enabling the SIR System in Air Bags and Seat Belts 12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations LF of the engine compartment, in the air cleaner duct. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions Mass Air Flow (MAF) Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1404 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1405 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1406 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1407 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1408 Mass Air Flow (MAF) Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1409 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1410 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1411 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1412 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1413 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1414 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1415 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1416 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1417 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1418 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1419 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1420 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1421 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1422 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1423 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1424 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1425 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1426 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1427 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1428 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1429 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1430 Mass Air Flow (MAF) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1431 Mass Air Flow (MAF) Sensor: Electrical Diagrams Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1432 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Page 1433 Mass Air Flow (MAF) Sensor: Description and Operation The Mass Air Flow (MAF) sensor measures the amount of air which passes through it. The PCM uses this information to determine the operating condition of the engine, to control fuel delivery. A large quantity of air indicates acceleration, while a small quantity indicates deceleration or idle. The scan tool reads the MAF value and displays it in grams per second (gm/s). At idle, it should read between 4 gm/s to 6 gm/s on a fully warmed up engine. Values should change rather quickly on acceleration, but values should remain fairly stable at any given RPM. A failure in the MAF sensor or circuit should set DTC P0101 Mass Air Flow (MAF) Sensor Performance, DTC P0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency, or DTC P0103 Mass Air Flow (MAF) Sensor Circuit High Frequency The MAF sensor is attached to the front (air inlet side) of the throttle body and is used to measure the amount of air entering the engine. The PCM uses this information to determine the operating condition of the engine and to control fuel delivery. For further information, refer to Information Sensors/Switches Description. See: Powertrain Management/Computers and Control Systems/Description and Operation/Information Sensors/Switches Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Page 1434 Mass Air Flow (MAF) Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the MAF sensor (1) electrical connector. 4. Remove the air inlet duct from the MAF sensor and the throttle body. 5. Remove the MAF sensor from the air filter housing. INSTALLATION PROCEDURE 1. Install the MAF sensor to the air filter housing. 2. Install the air inlet duct to the MAF sensor and throttle body. 3. Connect the IAT sensor (1) electrical connector. 4. Connect the MAF sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 89 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations RH side of the engine, below the intake plenum. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 1440 Camshaft Position Sensor: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 1441 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1444 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1445 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1446 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1447 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1448 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1449 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1450 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1451 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1452 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1453 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1454 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1455 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1456 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1457 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1458 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1459 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1460 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1461 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1462 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1463 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1464 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1465 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1466 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1467 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1468 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1469 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1470 Camshaft Position Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position (CMP) Sensor and Cam Signal Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor and Cam Signal The camshaft position sensor sends a cam signal to the PCM which uses it as a sync pulse to trigger the injectors in proper sequence. The PCM uses the CAM signal to indicate the position of the #1 piston during its intake stroke. This allows the PCM to calculate true Sequential Fuel Injection (SFI) mode of operation. If the PCM detects an incorrect CAM signal while the engine is running, DTC P0341 Camshaft Position (CMP) Sensor Performance will set. If the CAM signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection mode based on the last fuel injection pulse, and the engine will continue to run. The engine can be restarted and will run in the calculated sequential mode as long as the fault is present with a 1 in 6 chance of injector sequence being correct. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position (CMP) Sensor and Cam Signal > Page 1473 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The camshaft position sensor is located on the timing cover behind the water pump near the camshaft sprocket. As the camshaft sprocket turns, a magnet in it activates the Hall-effect switch in the camshaft position sensor. When the Hall-effect switch is activated, it grounds the signal line to the PCM, pulling the camshaft position sensor signal circuit's applied voltage low. This is interpreted as a CAM signal. The CAM signal is created as piston #1 is on the intake stroke. If the correct CAM signal is not received by the PCM, DTC P0341 will be set. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 1474 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the serpentine drive belt. 3. Loosen the power steering pump to gain access to the CMP. 4. Disconnect the sensor electrical connector. 5. Remove the attaching bolt. 6. Remove the sensor. 7. Inspect the sensor for wear, cracks or leakage if the sensor is not being replaced. INSTALLATION PROCEDURE 1. Lubricate the O-ring with clean engine oil and replace if damaged. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the camshaft position sensor. Tighten Tighten the retaining bolt to 10 N.m (88 lb in). 3. Connect the sensor electrical connector. 4. Install the power steering pump. 5. Reinstall the serpentine drive belt. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor 23 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1478 Coolant Temperature Sensor/Switch (For Computer): Locations LH side, top of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1481 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1482 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1483 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1484 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1485 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1486 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1487 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1488 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1489 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1490 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1491 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1492 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1493 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1494 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1495 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1496 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1497 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1498 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1499 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1500 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1501 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1502 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1503 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1504 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1505 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1506 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1507 Engine Coolant Temperature (ECT) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1508 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 1509 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The engine coolant temperature sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance (100,000 ohms at -40°C/-40°F) while high temperature causes low resistance (70 ohms at 130° C/266° F). The PCM supplies a 5.0 volt signal to the engine coolant temperature sensor through a resistor in the PCM and measures the voltage. The voltage will be high when the engine is cold, and low when the engine is hot. By measuring the voltage, the PCM calculates the engine coolant temperature. Engine coolant temperature affects most systems the PCM controls. The scan tool displays engine coolant temperature in degrees. After engine startup, the temperature should rise steadily to about 90°C (194°F) then stabilize when thermostat opens. If the engine has not been run for several hours (overnight), the engine coolant temperature and intake air temperature displays should be close to each other. A hard fault in the engine coolant sensor circuit should set DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage, or DTC P0118 Engine Coolant Temperature (ECT) Sensor Circuit High Voltage, an intermittent fault should set a DTC P1114 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent Low Voltage, or DTC P1115 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent High Voltage. The DTC Diagnostic Aids also contains a chart to test for sensor resistance values relative to temperature. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 1510 The ECT sensor (3) also contains another circuit which is used to operate the engine coolant temperature gauge located in the instrument panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 1511 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Relieve coolant pressure. 3. Disconnect the ECT sensor electrical connector. 4. Using a deep well socket and extension, remove the sensor. INSTALLATION PROCEDURE 1. Coat the engine coolant temperature sensor threads with sealer P/N 9985253 or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the sensor in the engine. Tighten Tighten the sensor to 23 N.m (17 lb ft). 3. Connect the ECT sensor electrical connector. 4. Start the engine. 5. Inspect for leaks. 6. Inspect the coolant level. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt Front Cover 89 in.lb Crankshaft Position Sensor Stud Side of Engine Block 98 in.lb Crankshaft Position Sensor Wiring Bracket Bolt 37 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 1517 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 1518 Locations View Crankshaft Position (24X) Sensor RH side of the engine, at the end of the crankshaft, behind the harmonic balancer. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 1519 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1522 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1523 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1524 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1525 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1526 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1527 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1528 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1529 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1530 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1531 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1532 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1533 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1534 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1535 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1536 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1537 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1538 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1539 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1540 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1541 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1542 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1543 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1544 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1545 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1546 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1547 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1548 Crankshaft Position Sensor (24X) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 7X Crankshaft Position (CKP) Sensor Crankshaft Position Sensor: Description and Operation 7X Crankshaft Position (CKP) Sensor The 7X crankshaft position sensor provides a signal used by the ignition control module. The ignition control module also uses the 7X crankshaft position sensor to generate 3X reference pulses which the PCM uses to calculate RPM and crankshaft position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 7X Crankshaft Position (CKP) Sensor > Page 1551 Crankshaft Position Sensor: Description and Operation 24X Crankshaft Position (CKP) Sensor 24X Crankshaft Position (CKP) Sensor The 24X crankshaft position (CKP) sensor (1) is used to improve idle spark control at engine speeds up to approximately 1600 RPM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure The Crankshaft Position System Variation compensating values are stored in the PCM non-volatile memory after a learn procedure has been performed. If the actual Crankshaft Position System Variation is not within the Crankshaft Position System Variation compensating values stored in the PCM, DTC P0300 may set. Refer to Diagnostic Aids for DTC P0300. The Crankshaft Position System Variation Learn Procedure should be performed if any of the following conditions are true: ^DTC P1336 is set. ^ The PCM has been replaced. ^ The engine has been replaced. ^ The crankshaft has been replaced. ^ The crankshaft harmonic balancer has been replaced. ^ The crankshaft position sensor has been replaced. Important: The scan tool Crankshaft Position System Variation Learn function will be inhibited if engine coolant temperature is less than 70°C (158°F). Allow the engine to warm to at least 70°C (158°F) before attempting the Crankshaft Position System Variation Learn Procedure. The scan tool Crankshaft Position System Variation Learn function will be inhibited if any Powertrain DTCs other than DTC P1336 are set before or during the Crankshaft Position System Variation Learn Procedure. Diagnose and repair any DTCs if set. Refer to applicable DTCs. The Crankshaft Position System Variation Learn function will be inhibited if the PCM detects a malfunction involving the camshaft position signal circuit, the 3X reference circuit, or the 24X reference circuit. If a malfunction has been indicated, refer to the following list to diagnose the system or sensor. ^ DTC P0336 Crankshaft Position (CKP) Sensor Circuit. ^ DTC P0341 Camshaft Position (CMP) Sensor Performance. ^ DTC P1374 Crankshaft Position (CKP) High to Low Resolution Frequency Correlation. The scan tool Crankshaft Position System Variation Learn function will not be enabled until engine coolant temperature reaches 70°C (158°F) Selecting the crankshaft position system variation learn procedure on the scan tool will command the PCM to enable CKP system variation learn fuel cutoff and allow the crankshaft position system variation compensating values to be stored in the PCM. The PCM must detect an engine speed of 5150 RPM (CKP system variation learn fuel cutoff) during the Crankshaft Position System Variation Learn Procedure to store the crankshaft position system variation compensating values and complete the procedure. Important: Block the drive wheels when performing the Crankshaft Position System Variation Learning Procedure in order to prevent personal injury. Set the vehicle parking brake when instructed by the scan tool. Quickly increase the accelerator pedal until wide open throttle is reached and hold. During the learn procedure the PCM will automatically control injector operation, when the RPM has reached a certain RPM the PCM will stop the fuel injectors from pulsing until the learn procedure is finished. When the PCM has learned the crankshaft variation the fuel injectors will return to normal operation and the engine will begin to accelerate again. Release the throttle when the engine reaches the second fuel cut off. Leaving the throttle open during the fuel cut off learn procedure will allow the engine to decel at an even rate. 1. Block the drive wheels. 2. Ensure the hood is closed. 3. Start the engine and allow engine coolant temperature to reach at least 70°C (158°F) 4. Turn OFF the ignition. 5. Select and enable the Crankshaft Position System Variation Learn Procedure with the scan tool. 6. Set the parking brake when instructed by the scan tool. 7. Start the vehicle. 8. Apply and hold the service brake pedal firmly. 9. Ensure the transaxle is in park. 10. Steadily increase the accelerator pedal until the fuel cutoff is reached at 5150 RPM and hold. Release the accelerator pedal after the second fuel cutoff has been reached. 11. The crankshaft position system variation compensating values are learned when the RPM decreases back to idle. If the procedure terminates. 12. Observe DTC status for DTC P1336. 13. If the scan tool indicates that DTC P1336 ran and passed, the Crankshaft Position System Variation Learn Procedure is complete. If the scan tool indicates DTC P1336 failed or not run, determine if other DTCs have set. If DTCs other than P1336 are not set, repeat the Crankshaft Position System Variation Learn Procedure as necessary. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 1554 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement (7X) REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Crank steering wheel fully to the left. 3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting. 4. Remove the right tire and wheel. 5. Disconnect the sensor electrical connector. 6. Remove the attaching bolt/screw. 7. Remove the sensor from engine. 8, Inspect for wear, cracks, or leakage if the sensor is not being replaced. INSTALLATION PROCEDURE 1. Lubricate the O-ring with clean engine oil before installation and replace if damaged. 2. Install the sensor to the block. 3. Reinstall the sensor attaching bolt. Tighten Tighten the bolt to 11 N.m (97 lb in). 4. Connect the sensor electrical connector. 5. Install the right tire and wheel. 6. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 1555 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement (24X) REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the serpentine drive belt from crankshaft pulley. 3. Raise the vehicle on hoist. Refer to Lifting and Jacking the Vehicle in General Information 4. Remove the crankshaft harmonic balancer. 5. Note the routing of sensor harness before removal. 6. Remove the harness retaining clip with bolt (1). 7. Disconnect the sensor electrical connector. 8, Remove the sensor bolts (4). 9. Remove the sensor. INSTALLATION PROCEDURE 1. Install the 24X crankshaft position sensor with bolts (4) and route harness as noted during removal. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the harness retaining clip with bolt (3). Tighten Tighten the bolts to 10 N.m (88 lb in). 3. Connect the sensor electrical connector. 4. Reinstall the balancer on the crankshaft. 5. Lower vehicle. 6. Reinstall the serpentine drive belt. 7. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Description and Operation EGR Valve Position Sensor: Description and Operation The Exhaust Gas Recirculation (EGR) pintle position sensor is an integral part of the EGR valve assembly. This sensor can not be serviced separately from the EGR valve assembly. EGR Pintle Position Sensor The PCM monitors the EGR valve pintle position input to ensure that the valve responds properly to commands from the PCM and to detect a fault if the pintle position sensor and control circuits are open or shorted. If the PCM detects a pintle position signal voltage outside the normal range of the pintle position sensor, or a signal voltage that is not within a tolerance considered acceptable for proper EGR system operation, the PCM will set DTC P1404 EGR valve stuck open. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Mounted in the fuel tank. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1562 Fuel Level Sensor: Description and Operation The fuel level sensor consists of the following components: float, the wire float arm, and the ceramic resistor card. The fuel level sensor is mounted on the modular fuel sender assembly and is used as an input to the PCM. The PCM uses this information as a fuel level input for Various diagnostics. In addition the PCM transmits the fuel level over the Class II communication circuit to the IP cluster. This information is used for the IP fuel gauge, and low fuel warning indicator if applicable. Fuel Level Sensor The Fuel Level Sensor(4) is mounted on the Modular Fuel Sender Assembly(s). The PCM uses the fuel level input for various diagnosis including the EVAP System. In addition the PCM transmits the fuel level over the Class II communication circuit to the IP Cluster. The low fuel level message may not appear if other messages are being commanded, such as the rear deck lid, driver or passenger doors ajar. Ensure that all doors and compartment lids are completely closed. For further information regarding the Fuel Level Sensor refer to Fuel Metering Modes of Operation. See: Powertrain Management/Fuel Delivery and Air Induction/Description and Operation/Fuel Metering/Fuel Metering Modes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1563 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure. See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 2. Remove the modular fuel sender assembly. 3. Remove the fuel level sensor (5) from the modular fuel sender. INSTALLATION PROCEDURE 1. Reinstall the fuel level sensor (5) to modular fuel sender. 2. Reinstall the fuel sender assembly. 3. Tighten the fuel filler cap. 4. Reconnect the negative battery cable. 5. Inspect for fuel leaks. 5.1. Turn the ignition ON for 2 seconds 5.2. Turn the ignition OFF for 10 seconds. 5.3. Turn the ignition ON. 5.4. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Fuel Tank Pressure (FTP) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Fuel Tank Pressure Sensor - 1 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor - 1 The Fuel Tank Pressure (FTP) sensor measures the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The sensor mounts at the top of the fuel tank sending unit. The PCM supplies a 5 volt reference voltage and ground to the sensor. The sensor provides a signal voltage between 0.1-4.9 volts to the PCM. When the air pressure in the fuel tank is equal to the outside air pressure, such as when the fuel fill cap is removed, the output voltage of the sensor will measure 1.3-1.7 volts. When the air pressure in the tank is 4.5 inches H20 (1.25 kPa), the sensor output voltage should measure 0.5 ± 0.2 volts (1.25 kPa). The sensor voltage increases to approximately 4.5 volts at 14 inches of H2O (-3.75 kpa). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Fuel Tank Pressure Sensor - 1 > Page 1569 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor - 2 Fuel Tank Pressure Sensor The Fuel Tank Pressure Sensor(6) is mounted on top the Modular Fuel Sender Assembly(S). The PCM uses the fuel tank pressure input for the EVAP System. The PCM supplies a 5 volt reference to the sensor and a sensor return (ground). The PCM monitors the signal circuit from the sensor with a voltage range from 0.1 volts to 4.9 volts. When the pressure inside the fuel tank is totally vented the pressure is equal to atmospheric pressure or approximately 1.3-1.7 volts. When the tank is pressurized the voltage can reach more than 4.5 volts. For further information regarding the Fuel Tank Pressure Sensor refer to Fuel Metering Modes of Operation, and EVAP Control System Operation Description. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Fuel Tank Pressure Sensor - 1 > Page 1570 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor - 3 Fuel Tank Pressure Sensor The Fuel Tank Pressure (FTP) sensor measures the difference between the air pressure, or vacuum, in the fuel tank and the outside air pressure. The sensor mounts at the top of the fuel tank sending unit. The PCM supplies a 5 volt reference voltage and ground to the sensor. The sensor provides a signal voltage between 0.1-4.9 volts to the PCM. When the air pressure in the fuel tank is equal to the outside air pressure, such as when the fuel fill cap is removed, the output voltage of the sensor will measure 1.3-1.7 volts. When the air pressure in the tank is 1.25 kPa (4.5 inches Hg), the sensor output voltage should measure 1.25 kPa (approx 0.5 volts). The sensor voltage increases to approximately 4.5 volts at -3.75 kPa (14 inches of Hg). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 1571 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the spare tire cover, the jack, and the spare tire. 3. Remove the trunk liner. 4. Remove the 7 nuts retaining the fuel sender access panel. 5. Remove the fuel sender access panel. 6. Disconnect the electrical connector from the fuel tank vapor pressure sensor. 7. Remove the fuel tank vapor pressure sensor (7) from modular fuel sender assembly. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 1572 1. Reinstall the new fuel tank vapor pressure sensor (7) to modular fuel sender. 2. Connect the electrical connector to fuel tank vapor pressure sensor 3. Reinstall the fuel sender access panel. 4. Reinstall the 7 nuts retaining the fuel sender access panel. Tighten Tighten the fuel sender access panel nuts to 10 N.m (88 lb in) 5. Reinstall the trunk liner. 6. Reinstall the spare tire, the jack, and the spare tire cover. 7. Reconnect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Intake Air Temperature (IAT) Sensor: Locations Intake Air Temperature (IAT) Sensor is in the air induction tube. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions Intake Air Temperature (IAT) Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1578 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1579 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1580 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1581 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1582 Intake Air Temperature (IAT) Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1583 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1584 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1585 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1586 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1587 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1588 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1589 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1590 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1591 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1592 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1593 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1594 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1595 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1596 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1597 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1598 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1599 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1600 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1601 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1602 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1603 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1604 Intake Air Temperature Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1605 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Page 1606 Intake Air Temperature (IAT) Sensor: Description and Operation The Intake Air Temperature (IAT) sensor is a thermistor which changes value based on the temperature of air entering the engine. Low temperature produces a high resistance (100,000 ohms at -40°C/-40°F), while high temperature causes low resistance (70 ohms at 130°C/266°F). The PCM supplies a 5.0 volt signal to the sensor through a resistor in the PCM and measures the voltage. The voltage will be high when the incoming air is cold, and low when the air is hot. By measuring the voltage, the PCM calculates the incoming air temperature. The IAT sensor signal is used to adjust spark timing according to incoming air density. The scan tool displays temperature of the air entering the engine, which should read close to ambient air temperature when the engine is cold, and rise as the underhood temperature increases. If the engine has not been run for several hours (overnight) the IAT sensor temperature and engine coolant temperature should read close to each other. A failure in the IAT sensor circuit should set DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage or DTC P0113 Intake Air Temperature (IAT) Sensor Circuit High Voltage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Page 1607 Intake Air Temperature (IAT) Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the IAT sensor electrical connector. 3. Carefully grasp the sensor and with a twisting and pulling motion, remove the IAT sensor from air intake duct. INSTALLATION PROCEDURE 1. Install the IAT sensor (snap into place). 2. Connect the IAT sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications knock Sensor 19 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations Knock Sensor: Component Locations Left Front Of Engine Knock Sensor (KS) Bank 1 Lower RR of the engine, below the exhaust manifold. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations > Page 1613 Knock Sensor: Connector Locations Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations > Page 1614 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1617 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1618 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1619 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1620 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1621 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1622 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1623 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1624 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1625 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1626 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1627 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1628 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1629 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1630 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1631 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1632 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1633 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1634 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1635 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1636 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1637 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1638 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1639 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1640 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1641 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1642 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1643 Knock Sensor (KS) 1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1644 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > General Information Knock Sensor: Description and Operation General Information The knock sensor detects abnormal vibration (spark knocking) in the engine. The sensor is located on the engine block near the cylinders. The sensor produces an AC output voltage which increases with the severity of the knock. This signal voltage is input to the PCM. The PCM then adjusts the Ignition Control (IC) timing to reduce spark knock. DTC P0325 Knock Sensor (KS) Circuit DTC P0327 Knock Sensor (KS) Circuit are designed to diagnose the PCM, the knock sensor, and related wiring, so problems encountered with the KS system should set a DTC. Refer to Knock Sensor (KS) System Description description of the knock sensor system. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > General Information > Page 1647 Knock Sensor: Description and Operation Operation The knock sensor detects abnormal vibration (spark knocking) in the engine. The knock sensor is mounted in the engine block near the cylinders and produce an AC signal under all engine operating conditions. The PCM contains integrated Knock Sensor (KS) diagnostic circuitry which uses the input signals from the knock sensors to detect engine detonation. This allows the PCM to retard Ignition Control (IC) spark timing based on the amplitude and frequency of the KS signal being received. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > General Information > Page 1648 Knock Sensor: Description and Operation Purpose Knock Sensor (KS) System Description Purpose Varying octane levels in todays gasoline may cause detonation in some engines. Detonation is caused by an uncontrolled explosion (burn) in the combustion chamber. This uncontrolled explosion could produce a flame front opposite that of the normal flame front produced by the spark plug. The rattling sound normally associated with detonation is the result of two or more opposing pressures (flame fronts) colliding within the combustion chamber. Though light detonation is sometimes considered normal, heavy detonation could result in engine damage. To control spark knock, a Knock Sensor (KS) system is used. This system is designed to retard spark timing when spark knock is detected in the engine. The KS system allows the engine to use maximum spark advance for optimal driveability and fuel economy. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 1649 Knock Sensor: Testing and Inspection The PCM calculates an average voltage the knock sensor signal and takes instantaneous signal voltage readings. The PCM uses the instantaneous signal voltage reading to determine the state of the knock sensor circuitry. If the knock sensor system is operating normally, the PCM should monitor instantaneous KS signal voltage readings varying outside a voltage range above and below the calculated average voltage. The following DTCs are used to diagnose the knock sensor system: ^ If the PCM malfunctions in a manner which will not allow proper diagnosis of the KS circuits, DTC P0325 will set. ^ DTC P0327 is designed to diagnose the knock sensor, and related wiring, so problems encountered with the KS system should set a DTC. However, if no DTC was set but the KS system is suspect because detonation was the customer's complaint, use the tables for P0327 to diagnose the Detonation/Spark Knock Symptom. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 1650 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting. 3. Disconnect the knock sensor wiring harness connector from the knock sensor. 4. Remove the knock sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Do Not apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. NOTE: Refer to Fastener Notice in Service Precautions. Knock Sensor (KS) System Deascription Purpose 1. Install the knock sensor into engine block. Tighten Tighten the knock sensor to 19 N.m (14 lb ft). 2. Connect the knock sensor wiring harness connector to the knock sensor. 3. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications Manifold Absolute Pressure (MAP) Sensor: Specifications Manifold Absolute Pressure (MAP) Sensor Retaining Bolt 3 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 1654 Manifold Absolute Pressure (MAP) Sensor: Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 1655 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions Manifold Absolute Pressure (MAP) Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1658 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1659 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1660 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1661 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1662 Manifold Absolute Pressure (MAP) Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1663 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1664 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1665 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1666 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1667 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1668 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1669 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1670 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1671 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1672 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1673 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1674 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1675 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1676 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1677 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1678 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1679 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1680 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1681 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1682 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1683 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1684 Manifold Air Pressure (MAP) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1685 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Page 1686 Manifold Absolute Pressure (MAP) Sensor: Description and Operation The Manifold Absolute Pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the PCM varies from below 2.0 volts at idle (high vacuum) to above 4.0 volts with the key ON, and the engine OFF, or at wide open throttle (low vacuum). The MAP sensor is used to determine manifold pressure changes while the linear EGR flow test diagnostic is being run, Refer to DTC P0401 Exhaust Gas Recirculation (EGR) Flow Insufficient, to determine engine vacuum level for other diagnostics and to determine Barometric Pressure (BARO). If the PCM detects a voltage that is lower than the possible range of the MAP sensor, DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage will be set. A signal voltage higher than the possible range of the sensor will set DTC P0108 Manifold Absolute Pressure (MAP) Sensor Circuit High Voltage. An intermittent low or high voltage will set DTC P1107 Manifold Absolute Pressure (MAP) Sensor Circuit Intermittent Low Voltage or DTC P1106 Manifold Absolute Pressure (MAP) Sensor Circuit Intermittent High Voltage respectively. The PCM can also detect a shifted MAP sensor. The PCM compares the MAP sensor signal to a calculated MAP based on throttle position and various engine load factors Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Page 1687 Manifold Absolute Pressure (MAP) Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the MAP sensor from the bracket. 2. Disconnect the MAP inlet vacuum hose. 3. Disconnect the MAP sensor electrical connector. INSTALLATION PROCEDURE 1. Connect the MAP sensor electrical connector. 2. Connect the inlet vacuum hose. 3. Position the MAP sensor to bracket and tighten fasteners. Tighten Tighten the MAP sensor fasteners to 3 N.m (27 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations Oil Level Sensor For ECM: Locations Front center of the engine oil pan. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 1691 Engine Oil Level Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 1695 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Heated Oxygen Sensors 41 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 1701 Locations View Heated Oxygen Sensor 1 (HO2S1) Rear of the engine, in the exhaust manifold. Heated Oxygen Sensor 2 (HO2A2) In the exhaust system, behind the catalytic converter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 1702 Oxygen Sensor: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 1703 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1706 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1707 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1708 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1709 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1710 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1711 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1712 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1713 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1714 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1715 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1716 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1717 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1718 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1719 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1720 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1721 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1722 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1723 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1724 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1725 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1726 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1727 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1728 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1729 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1730 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1731 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1732 Oxygen Sensor: Connector Views Heated Oxygen Sensor (HO2S2) 1 Heated Oxygen Sensor (HO2S2) 2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1733 Oxygen Sensor: Electrical Diagrams Schematic Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Fuel Control Heated Oxygen Sensor (HO2S 1) Oxygen Sensor: Description and Operation Fuel Control Heated Oxygen Sensor (HO2S 1) Fuel Controlled Heated Oxygen Sensor (H02S 1) The fuel control Heated Oxygen Sensor (HO2S 1) is mounted in the exhaust manifold where it can monitor the oxygen content of the exhaust gas stream. The oxygen present in the exhaust gas reacts with the sensor to produce a voltage output. This voltage should constantly fluctuate from approximately 100 mV (high oxygen content lean mixture) to 900 mV (low oxygen content rich mixture). The heated oxygen sensor voltage can be monitored with a scan tool. By monitoring the voltage output of the oxygen sensor, the PCM calculates what fuel mixture command to give to the injectors (lean mixture low HO2S voltage = rich command, rich mixture high HO2S voltage = lean command). The HO2S 1 circuit, if open, should set a DTC P0134 HO2S Circuit Insufficient Activity Sensor 1 and the scan tool will display a constant voltage between 400-500 mV. A constant voltage below 300 mV in the sensor circuit (circuit grounded) should set DTC P0131 HO2S Circuit Low Voltage Sensor 1, while a constant voltage above 800 mV in the circuit should set DTC P0132 HO2S Circuit High Voltage Sensor 1. A fault in the HO2S 1 heater circuit should cause DTC P0135 to set. The PCM can also detect HO2S response problems. If the response time of an HO2S is determined to be too slow, the PCM will store a DTC that indicates degraded HO2S performance. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Fuel Control Heated Oxygen Sensor (HO2S 1) > Page 1736 Oxygen Sensor: Description and Operation Catalyst Monitor Heated Oxygen Sensor (HO2S 2) To control emissions of Hydrocarbons (HC), Carbon Monoxide (CO), and oxides of nitrogen (NOx), a three-way catalytic converter is used. The catalyst within the converter promotes a chemical reaction which oxidizes the HG and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The PCM has the ability to monitor this process using the HO2S 1 and the HO2S 2. The HO2S 1 produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The HO2S 2 produces an output signal which indicates the oxygen storage capacity of the catalyst, this in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the HO2S 1 signal will be far more active than that produced by the HO2S 2. The catalyst monitor sensors operate the same as the fuel control sensors. Although the HO2S 2 main function is catalyst monitoring, it also plays a limited role in fuel control. If the sensor output indicates a voltage either above or below the 450 millivolt bias voltage for an extended period of time, the PCM will make a slight adjustment to fuel trim to ensure that fuel delivery is correct for catalyst monitoring. A problem with the HO2S 2 signal circuit should set DTC P0137 HO2S Circuit Low Voltage Sensor 2, DTC P0138 HO2S Circuit High Voltage Sensor 2, or DTC P0140 HO2S Circuit Insufficient Activity Sensor 2, depending on the specific condition. A fault in the heated oxygen sensor heater element or its ignition feed or ground will result in slower oxygen sensor response. This may cause erroneous Catalyst monitor diagnostic results. A fault in the HO2S 2 heater circuit should cause DTC P0141 HO2S Heater Performance Sensor 2 to set. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement (HO2S1) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement (HO2S1) TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Socket REMOVAL PROCEDURE (HO2S1) The heated oxygen sensor may be difficult to remove when engine temperature is below 48°C (120°F). Excessive force may damage threads in exhaust manifold or exhaust pipe. 1. Turn OFF the ignition. 2. Disconnect the electrical connector. IMPORTANT: A special anti seize compound is used on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine and if for any reason is to be reinstalled, the threads must have anti seize compound applied before reinstallation. 3. Using J 39194-B heated oxygen sensor socket carefully back out the heated oxygen sensor. INSTALLATION PROCEDURE (HO2S1) 1. Coat the threads of heated oxygen sensor/catalyst monitor with anti seize compound P/N 5613695, or equivalent if necessary. 2. Install the heated oxygen sensor. Tighten Tighten the HO2S 1 (Pre-catalytic converter) to 41 N.m (30 lb ft). 3. Connect the HO2S1 sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement (HO2S1) > Page 1739 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement (HO2S2) TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Socket REMOVAL PROCEDURE (HO2S2) The heated oxygen sensor may be difficult to remove when engine temperature is below 48°C (120°F). Excessive force may damage threads in exhaust manifold or exhaust pipe. 1. Turn OFF the ignition. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting. 3. Disconnect the sensor electrical connector. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine and if for any reason is to be reinstalled, the threads must have anti seize compound applied before reinstallation. 4. Using J 39194-B heated oxygen sensor socket carefully back out the heated oxygen sensor. INSTALLATION PROCEDURE (HO2S2) 1. Coat the threads of heated oxygen sensor/catalyst monitor with anti seize compound PIN 5613695, or equivalent if necessary. NOTE: Refer to Fastener Notice in Service Precautions. 2. Using J 39194-B heated oxygen sensor socket install the heated oxygen sensor. Tighten Tighten the HO2S2 to 41 N.m (30 lb ft). 3. Connect the HO2S2 sensor electrical connector. 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screws 2 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1743 Throttle Position Sensor: Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1744 Left Front Of Engine Top of the engine, on the throttle body assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1747 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1748 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1749 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1750 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1751 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1752 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1753 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1754 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1755 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1756 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1757 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1758 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1759 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1760 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1761 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1762 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1763 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1764 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1765 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1766 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1767 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1768 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1769 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1770 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1771 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1772 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1773 Throttle Position Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 1774 Throttle Position Sensor: Description and Operation The Throttle Position (TP) sensor is a potentiometer connected to the throttle shaft on the throttle body. By monitoring the voltage on the signal line, the PCM calculates throttle position. As the throttle valve angle is changed (accelerator pedal moved), the TP sensor signal also changes. At a closed throttle position, the output of the TP sensor is low. As the throttle valve opens, the output increases so that at Wide Open Throttle (WOT), the output voltage should be above 4.0 volts. The PCM calculates fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor may cause intermittent bursts of fuel from an injector and unstable idle because the PCM thinks the throttle is moving. A hard failure in the TP sensor 5.0 volt reference or signal circuits should set either a DTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage. A hard failure with the TP Sensor ground circuit may set DTCs DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage, DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage, DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage, or DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage. Once a DTC is set, the PCM will use an artificial default value based on engine RPM, engine load and mass air flow for throttle position and some vehicle performance will return. A high idle may result when either DTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage, or DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage is set. The PCM can detect intermittent TP sensor faults. DTC P1121 Throttle Position (TP) Sensor Circuit Intermittent High Voltage, or DTC P 1122 Throttle Position (TP) Sensor Circuit Intermittent Low Voltage will set it an intermittent high or low circuit failure is being detected. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 1775 The PCM can also detect a shifted TP sensor (2). The PCM monitors throttle position and compares the actual TP sensor reading to a predicted TP value calculated from engine speed. If the PCM detects an out of range condition, DTC P0121 Throttle Position (TP) Sensor Performance will be set. The non-adjustable TP sensor is mounted on the side of the throttle body opposite the throttle lever. It senses the throttle valve angle and relays that information to the PCM. Knowledge of the throttle angle is needed by the PCM to generate the required injector control signals (pulse). For further information, Refer to Information Sensors/Switches Description. See: Powertrain Management/Computers and Control Systems/Description and Operation/Information Sensors/Switches Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 1776 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the TP sensor electrical connector. 3. Remove the 2 TP sensor attaching screws. 4. Remove the TP sensor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 1777 5. Remove the TP sensor O-ring. INSTALLATION PROCEDURE 1. Install the TP sensor O-ring. 2. With the throttle valve in the normal closed idle position, install the TP sensor on the throttle body assembly. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 1778 3. Reinstall the 2 TP sensor attaching screws, using a thread-locking compound on the screws. Loctite (R) 262, GM P/N 1052624, or equivalent should be used. Tighten Tighten the TP sensor attaching screws to 2.0 N.m (18 lb in). 4. Connect the TP sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Inside the automatic transaxle Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1782 Park Neutral Position (PNP) Switch C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Speed Sensor to Case 106 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 1786 Vehicle Speed Sensor: Locations Locations View RR of the engine, on the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1789 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1790 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1791 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1792 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1793 Vehicle Speed Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1794 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1795 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1796 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1797 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1798 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1799 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1800 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1801 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1802 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1803 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1804 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1805 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1806 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1807 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1808 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1809 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1810 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1811 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1812 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1813 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1814 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1815 Vehicle Speed Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1816 Vehicle Speed Sensor: Service and Repair Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment 3. Remove the vehicle speed sensor wiring harness connector. 4. Remove the vehicle speed sensor bolt (9). 5. Remove the vehicle speed sensor (10) from the extension case. 6. Remove the O-ring (11) from the vehicle speed sensor(10). Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1817 1. Install the O-ring (111) to the vehicle speed sensor (10). 2. Install the vehicle speed sensor (10) to the extension case. Notice: Refer to Fastener Notice in Service Precautions 3. Install the vehicle speed sensor bolt (9). - Tighten the vehicle speed sensor bolt (9) to 12 Nm (106 inch lbs.). 4. Install the vehicle speed sensor wiring harness connector. 5. Install the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment 6. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Description and Operation EGR Valve Position Sensor: Description and Operation The Exhaust Gas Recirculation (EGR) pintle position sensor is an integral part of the EGR valve assembly. This sensor can not be serviced separately from the EGR valve assembly. EGR Pintle Position Sensor The PCM monitors the EGR valve pintle position input to ensure that the valve responds properly to commands from the PCM and to detect a fault if the pintle position sensor and control circuits are open or shorted. If the PCM detects a pintle position signal voltage outside the normal range of the pintle position sensor, or a signal voltage that is not within a tolerance considered acceptable for proper EGR system operation, the PCM will set DTC P1404 EGR valve stuck open. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations LF of the engine compartment, in the air cleaner duct. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions Mass Air Flow (MAF) Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1828 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1829 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1830 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1831 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1832 Mass Air Flow (MAF) Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1833 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1834 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1835 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1836 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1837 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1838 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1839 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1840 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1841 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1842 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1843 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1844 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1845 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1846 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1847 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1848 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1849 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1850 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1851 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1852 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1853 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1854 Mass Air Flow (MAF) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1855 Mass Air Flow (MAF) Sensor: Electrical Diagrams Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1856 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Page 1857 Mass Air Flow (MAF) Sensor: Description and Operation The Mass Air Flow (MAF) sensor measures the amount of air which passes through it. The PCM uses this information to determine the operating condition of the engine, to control fuel delivery. A large quantity of air indicates acceleration, while a small quantity indicates deceleration or idle. The scan tool reads the MAF value and displays it in grams per second (gm/s). At idle, it should read between 4 gm/s to 6 gm/s on a fully warmed up engine. Values should change rather quickly on acceleration, but values should remain fairly stable at any given RPM. A failure in the MAF sensor or circuit should set DTC P0101 Mass Air Flow (MAF) Sensor Performance, DTC P0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency, or DTC P0103 Mass Air Flow (MAF) Sensor Circuit High Frequency The MAF sensor is attached to the front (air inlet side) of the throttle body and is used to measure the amount of air entering the engine. The PCM uses this information to determine the operating condition of the engine and to control fuel delivery. For further information, refer to Information Sensors/Switches Description. See: Powertrain Management/Computers and Control Systems/Description and Operation/Information Sensors/Switches Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Page 1858 Mass Air Flow (MAF) Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the MAF sensor (1) electrical connector. 4. Remove the air inlet duct from the MAF sensor and the throttle body. 5. Remove the MAF sensor from the air filter housing. INSTALLATION PROCEDURE 1. Install the MAF sensor to the air filter housing. 2. Install the air inlet duct to the MAF sensor and throttle body. 3. Connect the IAT sensor (1) electrical connector. 4. Connect the MAF sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Component Locations Oil Pressure Switch (For Fuel Pump): Component Locations Engine Oil Pressure Indicator Switch (LA1) Front of the engine, above the starter. RPO LA1: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Engine Oil Pressure Indicator Switch (L36) Near generator. RPO L36: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Component Locations > Page 1863 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Component Locations > Page 1864 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 1865 Oil Pressure Switch (For Fuel Pump): Description and Operation Engine Oil Pressure Switch The PCM monitors the engine oil pressure switch (1) signal to determine if the engine oil pressure is OK. If the PCM determines that a low oil pressure condition exists, the PCM will communicate the information over the Class II circuit to the P cluster and it will illuminate the indicator lamp or initiate a message. The low oil pressure message may not appear if other messages are being commanded, such as the rear deck lid, driver or passenger doors ajar. Ensure that all doors and compartment lids are completely closed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screws 2 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1869 Throttle Position Sensor: Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1870 Left Front Of Engine Top of the engine, on the throttle body assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1873 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1874 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1875 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1876 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1877 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1878 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1879 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1880 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1881 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1882 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1883 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1884 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1885 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1886 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1887 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1888 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1889 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1890 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1891 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1892 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1893 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1894 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1895 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1896 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1897 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1898 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1899 Throttle Position Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 1900 Throttle Position Sensor: Description and Operation The Throttle Position (TP) sensor is a potentiometer connected to the throttle shaft on the throttle body. By monitoring the voltage on the signal line, the PCM calculates throttle position. As the throttle valve angle is changed (accelerator pedal moved), the TP sensor signal also changes. At a closed throttle position, the output of the TP sensor is low. As the throttle valve opens, the output increases so that at Wide Open Throttle (WOT), the output voltage should be above 4.0 volts. The PCM calculates fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor may cause intermittent bursts of fuel from an injector and unstable idle because the PCM thinks the throttle is moving. A hard failure in the TP sensor 5.0 volt reference or signal circuits should set either a DTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage. A hard failure with the TP Sensor ground circuit may set DTCs DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage, DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage, DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage, or DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage. Once a DTC is set, the PCM will use an artificial default value based on engine RPM, engine load and mass air flow for throttle position and some vehicle performance will return. A high idle may result when either DTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage, or DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage is set. The PCM can detect intermittent TP sensor faults. DTC P1121 Throttle Position (TP) Sensor Circuit Intermittent High Voltage, or DTC P 1122 Throttle Position (TP) Sensor Circuit Intermittent Low Voltage will set it an intermittent high or low circuit failure is being detected. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 1901 The PCM can also detect a shifted TP sensor (2). The PCM monitors throttle position and compares the actual TP sensor reading to a predicted TP value calculated from engine speed. If the PCM detects an out of range condition, DTC P0121 Throttle Position (TP) Sensor Performance will be set. The non-adjustable TP sensor is mounted on the side of the throttle body opposite the throttle lever. It senses the throttle valve angle and relays that information to the PCM. Knowledge of the throttle angle is needed by the PCM to generate the required injector control signals (pulse). For further information, Refer to Information Sensors/Switches Description. See: Powertrain Management/Computers and Control Systems/Description and Operation/Information Sensors/Switches Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 1902 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the TP sensor electrical connector. 3. Remove the 2 TP sensor attaching screws. 4. Remove the TP sensor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 1903 5. Remove the TP sensor O-ring. INSTALLATION PROCEDURE 1. Install the TP sensor O-ring. 2. With the throttle valve in the normal closed idle position, install the TP sensor on the throttle body assembly. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 1904 3. Reinstall the 2 TP sensor attaching screws, using a thread-locking compound on the screws. Loctite (R) 262, GM P/N 1052624, or equivalent should be used. Tighten Tighten the TP sensor attaching screws to 2.0 N.m (18 lb in). 4. Connect the TP sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 89 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations RH side of the engine, below the intake plenum. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 1911 Camshaft Position Sensor: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 1912 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1915 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1916 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1917 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1918 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1919 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1920 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1921 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1922 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1923 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1924 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1925 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1926 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1927 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1928 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1929 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1930 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1931 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1932 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1933 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1934 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1935 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1936 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1937 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1938 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1939 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1940 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1941 Camshaft Position Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position (CMP) Sensor and Cam Signal Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor and Cam Signal The camshaft position sensor sends a cam signal to the PCM which uses it as a sync pulse to trigger the injectors in proper sequence. The PCM uses the CAM signal to indicate the position of the #1 piston during its intake stroke. This allows the PCM to calculate true Sequential Fuel Injection (SFI) mode of operation. If the PCM detects an incorrect CAM signal while the engine is running, DTC P0341 Camshaft Position (CMP) Sensor Performance will set. If the CAM signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection mode based on the last fuel injection pulse, and the engine will continue to run. The engine can be restarted and will run in the calculated sequential mode as long as the fault is present with a 1 in 6 chance of injector sequence being correct. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position (CMP) Sensor and Cam Signal > Page 1944 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The camshaft position sensor is located on the timing cover behind the water pump near the camshaft sprocket. As the camshaft sprocket turns, a magnet in it activates the Hall-effect switch in the camshaft position sensor. When the Hall-effect switch is activated, it grounds the signal line to the PCM, pulling the camshaft position sensor signal circuit's applied voltage low. This is interpreted as a CAM signal. The CAM signal is created as piston #1 is on the intake stroke. If the correct CAM signal is not received by the PCM, DTC P0341 will be set. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 1945 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the serpentine drive belt. 3. Loosen the power steering pump to gain access to the CMP. 4. Disconnect the sensor electrical connector. 5. Remove the attaching bolt. 6. Remove the sensor. 7. Inspect the sensor for wear, cracks or leakage if the sensor is not being replaced. INSTALLATION PROCEDURE 1. Lubricate the O-ring with clean engine oil and replace if damaged. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the camshaft position sensor. Tighten Tighten the retaining bolt to 10 N.m (88 lb in). 3. Connect the sensor electrical connector. 4. Install the power steering pump. 5. Reinstall the serpentine drive belt. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt Front Cover 89 in.lb Crankshaft Position Sensor Stud Side of Engine Block 98 in.lb Crankshaft Position Sensor Wiring Bracket Bolt 37 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 1951 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 1952 Locations View Crankshaft Position (24X) Sensor RH side of the engine, at the end of the crankshaft, behind the harmonic balancer. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 1953 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1956 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1957 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1958 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1959 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1960 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1961 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1962 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1963 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1964 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1965 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1966 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1967 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1968 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1969 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1970 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1971 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1972 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1973 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1974 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1975 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1976 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1977 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1978 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1979 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1980 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1981 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1982 Crankshaft Position Sensor (24X) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 7X Crankshaft Position (CKP) Sensor Crankshaft Position Sensor: Description and Operation 7X Crankshaft Position (CKP) Sensor The 7X crankshaft position sensor provides a signal used by the ignition control module. The ignition control module also uses the 7X crankshaft position sensor to generate 3X reference pulses which the PCM uses to calculate RPM and crankshaft position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 7X Crankshaft Position (CKP) Sensor > Page 1985 Crankshaft Position Sensor: Description and Operation 24X Crankshaft Position (CKP) Sensor 24X Crankshaft Position (CKP) Sensor The 24X crankshaft position (CKP) sensor (1) is used to improve idle spark control at engine speeds up to approximately 1600 RPM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure The Crankshaft Position System Variation compensating values are stored in the PCM non-volatile memory after a learn procedure has been performed. If the actual Crankshaft Position System Variation is not within the Crankshaft Position System Variation compensating values stored in the PCM, DTC P0300 may set. Refer to Diagnostic Aids for DTC P0300. The Crankshaft Position System Variation Learn Procedure should be performed if any of the following conditions are true: ^DTC P1336 is set. ^ The PCM has been replaced. ^ The engine has been replaced. ^ The crankshaft has been replaced. ^ The crankshaft harmonic balancer has been replaced. ^ The crankshaft position sensor has been replaced. Important: The scan tool Crankshaft Position System Variation Learn function will be inhibited if engine coolant temperature is less than 70°C (158°F). Allow the engine to warm to at least 70°C (158°F) before attempting the Crankshaft Position System Variation Learn Procedure. The scan tool Crankshaft Position System Variation Learn function will be inhibited if any Powertrain DTCs other than DTC P1336 are set before or during the Crankshaft Position System Variation Learn Procedure. Diagnose and repair any DTCs if set. Refer to applicable DTCs. The Crankshaft Position System Variation Learn function will be inhibited if the PCM detects a malfunction involving the camshaft position signal circuit, the 3X reference circuit, or the 24X reference circuit. If a malfunction has been indicated, refer to the following list to diagnose the system or sensor. ^ DTC P0336 Crankshaft Position (CKP) Sensor Circuit. ^ DTC P0341 Camshaft Position (CMP) Sensor Performance. ^ DTC P1374 Crankshaft Position (CKP) High to Low Resolution Frequency Correlation. The scan tool Crankshaft Position System Variation Learn function will not be enabled until engine coolant temperature reaches 70°C (158°F) Selecting the crankshaft position system variation learn procedure on the scan tool will command the PCM to enable CKP system variation learn fuel cutoff and allow the crankshaft position system variation compensating values to be stored in the PCM. The PCM must detect an engine speed of 5150 RPM (CKP system variation learn fuel cutoff) during the Crankshaft Position System Variation Learn Procedure to store the crankshaft position system variation compensating values and complete the procedure. Important: Block the drive wheels when performing the Crankshaft Position System Variation Learning Procedure in order to prevent personal injury. Set the vehicle parking brake when instructed by the scan tool. Quickly increase the accelerator pedal until wide open throttle is reached and hold. During the learn procedure the PCM will automatically control injector operation, when the RPM has reached a certain RPM the PCM will stop the fuel injectors from pulsing until the learn procedure is finished. When the PCM has learned the crankshaft variation the fuel injectors will return to normal operation and the engine will begin to accelerate again. Release the throttle when the engine reaches the second fuel cut off. Leaving the throttle open during the fuel cut off learn procedure will allow the engine to decel at an even rate. 1. Block the drive wheels. 2. Ensure the hood is closed. 3. Start the engine and allow engine coolant temperature to reach at least 70°C (158°F) 4. Turn OFF the ignition. 5. Select and enable the Crankshaft Position System Variation Learn Procedure with the scan tool. 6. Set the parking brake when instructed by the scan tool. 7. Start the vehicle. 8. Apply and hold the service brake pedal firmly. 9. Ensure the transaxle is in park. 10. Steadily increase the accelerator pedal until the fuel cutoff is reached at 5150 RPM and hold. Release the accelerator pedal after the second fuel cutoff has been reached. 11. The crankshaft position system variation compensating values are learned when the RPM decreases back to idle. If the procedure terminates. 12. Observe DTC status for DTC P1336. 13. If the scan tool indicates that DTC P1336 ran and passed, the Crankshaft Position System Variation Learn Procedure is complete. If the scan tool indicates DTC P1336 failed or not run, determine if other DTCs have set. If DTCs other than P1336 are not set, repeat the Crankshaft Position System Variation Learn Procedure as necessary. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 1988 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement (7X) REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Crank steering wheel fully to the left. 3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting. 4. Remove the right tire and wheel. 5. Disconnect the sensor electrical connector. 6. Remove the attaching bolt/screw. 7. Remove the sensor from engine. 8, Inspect for wear, cracks, or leakage if the sensor is not being replaced. INSTALLATION PROCEDURE 1. Lubricate the O-ring with clean engine oil before installation and replace if damaged. 2. Install the sensor to the block. 3. Reinstall the sensor attaching bolt. Tighten Tighten the bolt to 11 N.m (97 lb in). 4. Connect the sensor electrical connector. 5. Install the right tire and wheel. 6. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 1989 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement (24X) REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the serpentine drive belt from crankshaft pulley. 3. Raise the vehicle on hoist. Refer to Lifting and Jacking the Vehicle in General Information 4. Remove the crankshaft harmonic balancer. 5. Note the routing of sensor harness before removal. 6. Remove the harness retaining clip with bolt (1). 7. Disconnect the sensor electrical connector. 8, Remove the sensor bolts (4). 9. Remove the sensor. INSTALLATION PROCEDURE 1. Install the 24X crankshaft position sensor with bolts (4) and route harness as noted during removal. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the harness retaining clip with bolt (3). Tighten Tighten the bolts to 10 N.m (88 lb in). 3. Connect the sensor electrical connector. 4. Reinstall the balancer on the crankshaft. 5. Lower vehicle. 6. Reinstall the serpentine drive belt. 7. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Switch Lock Cylinder - Dash Mounted Ignition Switch Lock Cylinder: Service and Repair Ignition Switch Lock Cylinder - Dash Mounted IGNITION SWITCH LOCK CYLINDER REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the body control module (BCM) theft deterrent relearn procedure whenever you replace the ignition switch lock cylinder. See: Computers and Control Systems/Body Control Module/Service and Repair/Procedures/Body Control Module (BCM) Programming/RPO Configuration 1. Disconnect the negative battery cable. 2. Remove the instrument panel (I/P) cluster trim plate. 3. Insert the key and turn the ignition lock cylinder to the ON/RUN position. 4. Using a small curved tool or an L-shaped hex wrench, depress and hold the detent on the ignition lock cylinder. Access the detent by placing the tool through the I/P opening to the right of the ignition switch. If you cannot locate the detent with the tool, lower the ignition switch away from the I/P. Refer to Ignition Switch Replacement. 5. Using the key as an aid, pull to remove the lock cylinder from the switch. 6. Remove the key from the lock cylinder. 7. If the cylinder does not rotate or is seized, follow the procedure in the ignition switch replacement. Refer to Ignition Switch Replacement. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Switch Lock Cylinder - Dash Mounted > Page 1995 1. Code the ignition lock cylinder, if necessary. Refer to Key and Lock Cylinder Coding. 2. Insert the key and turn the lock cylinder to the ON/RUN position. 3. Position the lock cylinder to the ignition switch. Press the cylinder into place. If you turned the key slightly while removing the lock cylinder, you may have to align the white colored ignition switch rotor (1) with the lock cylinder (2). You can rotate the ignition switch rotor (1) with your finger. 4. Turn the key to the OFF position and remove the key. 5. Install the I/P cluster trim plate. 6. Connect the negative battery cable. 7. If you installed a new lock cylinder, perform the BCM theft deterrent relearn procedure. See: Computers and Control Systems/Body Control Module/Service and Repair/Procedures/Body Control Module (BCM) Programming/RPO Configuration Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Switch Lock Cylinder - Dash Mounted > Page 1996 Ignition Switch Lock Cylinder: Service and Repair Programming/Learn Procedures Programming Replacement Lock Cylinder, BCM or PCM IMPORTANT: Reprogram the body control module (BCM) with the proper RPO configurations before you perform the learn procedures. When you replace the BCM, the module will learn Passlock Sensor Data Code immediately. However, the existing PCM must learn the new fuel continue password. When you replace a PCM, after programming, these modules will learn the incoming fuel continue password immediately upon receipt of a password message. Once a password message is received, and a password is learned, perform the learn procedure again if you want to change this password. A PCM which was previously installed in another vehicle will have learned the other vehicle's fuel continue password, and will require a learn procedure after programming in order to learn the current vehicle's password. 10 Minute Re-Learn Procedure Use this procedure after replacing any of the following components: 1. Lock Cylinders/Passlock Sensors 2. BCM 3. PCM Tech 2 Programming Procedure Use the following procedures in order to program the BCM with the Tech 2 equipment. 1. Connect the Tech 2 Diagnostic tool. 2. Select Request Information under Service Programming. 3. Disconnect the Tech 2 from the vehicle and connect it to a Techline Terminal. 4. On the Techline Terminal, select Theft Module Re-Learn under Service Programming. 5. Disconnect the Tech 2 from the Techline Terminal and connect the Tech 2 to the vehicle. 6. Turn ON the ignition, with the engine OFF. 7. Select VTD Re-Learn under Service Programming. 8. At this point you may disconnect the Tech 2, the Tech 2 is no longer required. 9. Observe the Security telltale, after approximately 10 minutes the telltale will turn OFF. The vehicle is now ready to relearn the Passlock Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. 10. Turn OFF the ignition, and wait 5 seconds. 11. Start the engine. (The vehicle has now learned keys). 12. Using a scan tool, clear any DTCs. 30 Minute Re-Learn Procedure Use this procedure after replacing lock cylinders, Passlock Module/BCM or the PCM (if necessary - see note above). 1. Turn ON the ignition, with the engine OFF. 2. Attempt to start the engine, then release the key to ON (The vehicle will not start). 3. Observe the Security telltale, after approximately 10 minutes the telltale will turn OFF. 4. Turn OFF the ignition, and wait 5 seconds. 5. Repeat steps 1-4 two more times, for a total of 3 cycles and 30 minutes. The vehicle is now ready to relearn the Passlock Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. IMPORTANT: The vehicle learns the Passlock Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. You must turn the ignition OFF before attempting to start the vehicle. 6. Start the engine. (The vehicle has now learned the Passlock Sensor Data Code and/or password.) 7. Using a scan tool, clear any DTCs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications knock Sensor 19 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations Knock Sensor: Component Locations Left Front Of Engine Knock Sensor (KS) Bank 1 Lower RR of the engine, below the exhaust manifold. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations > Page 2002 Knock Sensor: Connector Locations Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations > Page 2003 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2006 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2007 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2008 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2009 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2010 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2011 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2012 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2013 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2014 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2015 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2016 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2017 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2018 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2019 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2020 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2021 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2022 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2023 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2024 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2025 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2026 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2027 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2028 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2029 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2030 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2031 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2032 Knock Sensor (KS) 1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2033 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > General Information Knock Sensor: Description and Operation General Information The knock sensor detects abnormal vibration (spark knocking) in the engine. The sensor is located on the engine block near the cylinders. The sensor produces an AC output voltage which increases with the severity of the knock. This signal voltage is input to the PCM. The PCM then adjusts the Ignition Control (IC) timing to reduce spark knock. DTC P0325 Knock Sensor (KS) Circuit DTC P0327 Knock Sensor (KS) Circuit are designed to diagnose the PCM, the knock sensor, and related wiring, so problems encountered with the KS system should set a DTC. Refer to Knock Sensor (KS) System Description description of the knock sensor system. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > General Information > Page 2036 Knock Sensor: Description and Operation Operation The knock sensor detects abnormal vibration (spark knocking) in the engine. The knock sensor is mounted in the engine block near the cylinders and produce an AC signal under all engine operating conditions. The PCM contains integrated Knock Sensor (KS) diagnostic circuitry which uses the input signals from the knock sensors to detect engine detonation. This allows the PCM to retard Ignition Control (IC) spark timing based on the amplitude and frequency of the KS signal being received. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > General Information > Page 2037 Knock Sensor: Description and Operation Purpose Knock Sensor (KS) System Description Purpose Varying octane levels in todays gasoline may cause detonation in some engines. Detonation is caused by an uncontrolled explosion (burn) in the combustion chamber. This uncontrolled explosion could produce a flame front opposite that of the normal flame front produced by the spark plug. The rattling sound normally associated with detonation is the result of two or more opposing pressures (flame fronts) colliding within the combustion chamber. Though light detonation is sometimes considered normal, heavy detonation could result in engine damage. To control spark knock, a Knock Sensor (KS) system is used. This system is designed to retard spark timing when spark knock is detected in the engine. The KS system allows the engine to use maximum spark advance for optimal driveability and fuel economy. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Page 2038 Knock Sensor: Testing and Inspection The PCM calculates an average voltage the knock sensor signal and takes instantaneous signal voltage readings. The PCM uses the instantaneous signal voltage reading to determine the state of the knock sensor circuitry. If the knock sensor system is operating normally, the PCM should monitor instantaneous KS signal voltage readings varying outside a voltage range above and below the calculated average voltage. The following DTCs are used to diagnose the knock sensor system: ^ If the PCM malfunctions in a manner which will not allow proper diagnosis of the KS circuits, DTC P0325 will set. ^ DTC P0327 is designed to diagnose the knock sensor, and related wiring, so problems encountered with the KS system should set a DTC. However, if no DTC was set but the KS system is suspect because detonation was the customer's complaint, use the tables for P0327 to diagnose the Detonation/Spark Knock Symptom. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Page 2039 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting. 3. Disconnect the knock sensor wiring harness connector from the knock sensor. 4. Remove the knock sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Do Not apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. NOTE: Refer to Fastener Notice in Service Precautions. Knock Sensor (KS) System Deascription Purpose 1. Install the knock sensor into engine block. Tighten Tighten the knock sensor to 19 N.m (14 lb ft). 2. Connect the knock sensor wiring harness connector to the knock sensor. 3. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Inflatable Restraint Side Impact Sensor (LH) (SIS) Fasteners 10 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 2044 Inflatable Restraint Side Impact Sensor (SIS) (AJ7) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 2045 Impact Sensor: Service Precautions CAUTION: Be careful when you handle a sensor. Do not strike or bit a sensor. Before applying power to a sensor: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the sensor horizontally on the mounting surface. ^ Point the arrow on the sensor toward the front of the vehicle. ^ Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 2046 Impact Sensor: Description and Operation INFLATABLE RESTRAINT SIDE IMPACT SENSOR (SIS) The inflatable restraint Side Impact Sensor (SIS) is crash-sensing device used in the detection of side impact collisions. The SIS is located in the LH B pillar. The inflatable restraint side impact sensor is used to perform the following functions: ^ Side Impact Crash Detection - The SIS monitors vehicle velocity changes to detect side impact crashes that are severe enough to warrant deployment. ^ Side Air Bag System Status Communication - The SDM monitors the SIS through two interface circuits. The SIS can communicate the status of the side impact air bag system to the SDM. The SIS connects to the SIR wiring harness using a 2-way connector. The SIS receives power from the SDM when the ignition is ON. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Sensor Replacement Guidelines Impact Sensor: Service and Repair Sensor Replacement Guidelines Preliminary, Early Release Information The Inflatable Restraint Side Impact Sensor (SIS) replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. In this case, a moderate collision where the side of the vehicle, near the LH B pillar, is crushed, bent, or damaged due to a collision, requires replacement of the sensor. The sensor must be replaced whether a driver side air bag has deployed or if the sensor seems to be undamaged. Sensor damage which is not visible, such as a slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the sensor. Do not try to determine whether the sensor is undamaged, replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Sensor Replacement Guidelines > Page 2049 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement INFLATABLE RESTRAINT SIDE IMPACT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the center pillar lower trim. 3. Remove the Connector Position Assurance (CPA) from the inflatable restraint side impact sensor yellow 2-way harness connector. 4. Disconnect the inflatable restraint side impact sensor wiring harness connector. 5. Loosen the two inflatable restraint side impact sensor fasteners (2). 6. Remove the inflatable restraint side impact sensor (1) from the center pillar (3). INSTALLATION PROCEDURE 1. Install the inflatable restraint side impact sensor (1) to the center pillar (3). 2. Tighten the two inflatable restraint side impact sensor (1) fasteners (2). 3. Connect the inflatable restraint side impact sensor yellow 2-way harness connector. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the CPA to the inflatable restraint side impact sensor yellow 2-way connector. Tighten Use only hand tools to tighten the fasteners to 10 N.m (89 lb in). 5. Install the center pillar lower trim. 6. Enable the SIR system. Refer to Enabling the SIR System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams Seat Belt Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Switch Lock Cylinder - Dash Mounted Ignition Switch Lock Cylinder: Service and Repair Ignition Switch Lock Cylinder - Dash Mounted IGNITION SWITCH LOCK CYLINDER REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the body control module (BCM) theft deterrent relearn procedure whenever you replace the ignition switch lock cylinder. See: Body and Frame/Body Control Systems/Body Control Module/Service and Repair/Procedures/Body Control Module (BCM) Programming/RPO Configuration 1. Disconnect the negative battery cable. 2. Remove the instrument panel (I/P) cluster trim plate. 3. Insert the key and turn the ignition lock cylinder to the ON/RUN position. 4. Using a small curved tool or an L-shaped hex wrench, depress and hold the detent on the ignition lock cylinder. Access the detent by placing the tool through the I/P opening to the right of the ignition switch. If you cannot locate the detent with the tool, lower the ignition switch away from the I/P. Refer to Ignition Switch Replacement. 5. Using the key as an aid, pull to remove the lock cylinder from the switch. 6. Remove the key from the lock cylinder. 7. If the cylinder does not rotate or is seized, follow the procedure in the ignition switch replacement. Refer to Ignition Switch Replacement. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Switch Lock Cylinder - Dash Mounted > Page 2063 1. Code the ignition lock cylinder, if necessary. Refer to Key and Lock Cylinder Coding. 2. Insert the key and turn the lock cylinder to the ON/RUN position. 3. Position the lock cylinder to the ignition switch. Press the cylinder into place. If you turned the key slightly while removing the lock cylinder, you may have to align the white colored ignition switch rotor (1) with the lock cylinder (2). You can rotate the ignition switch rotor (1) with your finger. 4. Turn the key to the OFF position and remove the key. 5. Install the I/P cluster trim plate. 6. Connect the negative battery cable. 7. If you installed a new lock cylinder, perform the BCM theft deterrent relearn procedure. See: Body and Frame/Body Control Systems/Body Control Module/Service and Repair/Procedures/Body Control Module (BCM) Programming/RPO Configuration Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Switch Lock Cylinder - Dash Mounted > Page 2064 Ignition Switch Lock Cylinder: Service and Repair Programming/Learn Procedures Programming Replacement Lock Cylinder, BCM or PCM IMPORTANT: Reprogram the body control module (BCM) with the proper RPO configurations before you perform the learn procedures. When you replace the BCM, the module will learn Passlock Sensor Data Code immediately. However, the existing PCM must learn the new fuel continue password. When you replace a PCM, after programming, these modules will learn the incoming fuel continue password immediately upon receipt of a password message. Once a password message is received, and a password is learned, perform the learn procedure again if you want to change this password. A PCM which was previously installed in another vehicle will have learned the other vehicle's fuel continue password, and will require a learn procedure after programming in order to learn the current vehicle's password. 10 Minute Re-Learn Procedure Use this procedure after replacing any of the following components: 1. Lock Cylinders/Passlock Sensors 2. BCM 3. PCM Tech 2 Programming Procedure Use the following procedures in order to program the BCM with the Tech 2 equipment. 1. Connect the Tech 2 Diagnostic tool. 2. Select Request Information under Service Programming. 3. Disconnect the Tech 2 from the vehicle and connect it to a Techline Terminal. 4. On the Techline Terminal, select Theft Module Re-Learn under Service Programming. 5. Disconnect the Tech 2 from the Techline Terminal and connect the Tech 2 to the vehicle. 6. Turn ON the ignition, with the engine OFF. 7. Select VTD Re-Learn under Service Programming. 8. At this point you may disconnect the Tech 2, the Tech 2 is no longer required. 9. Observe the Security telltale, after approximately 10 minutes the telltale will turn OFF. The vehicle is now ready to relearn the Passlock Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. 10. Turn OFF the ignition, and wait 5 seconds. 11. Start the engine. (The vehicle has now learned keys). 12. Using a scan tool, clear any DTCs. 30 Minute Re-Learn Procedure Use this procedure after replacing lock cylinders, Passlock Module/BCM or the PCM (if necessary - see note above). 1. Turn ON the ignition, with the engine OFF. 2. Attempt to start the engine, then release the key to ON (The vehicle will not start). 3. Observe the Security telltale, after approximately 10 minutes the telltale will turn OFF. 4. Turn OFF the ignition, and wait 5 seconds. 5. Repeat steps 1-4 two more times, for a total of 3 cycles and 30 minutes. The vehicle is now ready to relearn the Passlock Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. IMPORTANT: The vehicle learns the Passlock Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. You must turn the ignition OFF before attempting to start the vehicle. 6. Start the engine. (The vehicle has now learned the Passlock Sensor Data Code and/or password.) 7. Using a scan tool, clear any DTCs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Fluid Pressure Sensor/Switch: Specifications TFP Switch to Case 120 ft.lb TFP Switch to Case Cover 106 in.lb TFP Switch to Valve Body 70 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 2076 Fluid Pressure Sensor/Switch: Locations Internal Electronic Component Locations Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Fluid Pressure Man Vlv Position Switch Connector, Harness Side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Fluid Pressure Man Vlv Position Switch Connector, Harness Side > Page 2079 Fluid Pressure Sensor/Switch: Diagrams 4T65-E Automatic Transaxle Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Fluid Pressure Manual Valve Position Switch Replacement Fluid Pressure Sensor/Switch: Service and Repair Fluid Pressure Manual Valve Position Switch Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the control valve body bolts (375, 379 and 381) that mount the fluid pressure manual valve position switch to the control valve body (300). 4. Carefully remove the fluid pressure manual valve position switch (395). Handle the switch carefully, the fluid pressure manual valve position switch is very delicate. 5. Inspect the fluid pressure manual valve position switch (395) for the following conditions: - Damaged electrical connector terminals - Damaged seals - Damaged switch membranes - Debris on the switch membranes Installation Procedure 1. Carefully install the fluid pressure manual valve position switch (395). Handle the switch carefully, the fluid pressure manual valve position switch is very delicate. Notice: Refer to Fastener Notice in Service Precautions 2. Install the control valve body bolts (375, 379, and 381) that mount the fluid pressure manual valve position switch to the control valve body (300). - Tighten the control valve body bolt (375) to 12 Nm (106 inch lbs.). - Tighten the control valve body bolt (379) to 16 Nm (106 inch lbs.). - Tighten the control valve body bolt (381) to 8 Nm (70 inch lbs.). 3. Connect the transaxle wiring harness. 4. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Fluid Pressure Manual Valve Position Switch Replacement > Page 2082 Fluid Pressure Sensor/Switch: Service and Repair Pressure Control Solenoid Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the pressure control solenoid (322). Installation Procedure 1. Install the pressure control solenoid (322). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Inside the automatic transaxle Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2086 Park Neutral Position (PNP) Switch C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 2090 Transmission Speed Sensor: Service and Repair Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the input speed sensor clip (441) from the case cover. 4. Remove the input speed sensor (440) from the case cover. 5. Inspect the input speed sensor (440) for the following conditions: - Damaged or missing magnet - Damaged housing - Bent or missing electrical terminals - Damaged speed sensor clip (441) Installation Procedure 1. Install the input speed sensor (440) into the case cover. 2. Install the input speed sensor clip (441) into the case cover. 3. Connect the transaxle wiring harness. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 2091 4. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Automatic Transaxle Fluid Temperature (TFT) Sensor Transmission Temperature Sensor/Switch: Locations Automatic Transaxle Fluid Temperature (TFT) Sensor Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Automatic Transaxle Fluid Temperature (TFT) Sensor > Page 2096 Transmission Temperature Sensor/Switch: Locations Transaxle Fluid Temperature (TFT) Sensor Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 2097 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 2098 Transmission Temperature Sensor/Switch: Service and Repair Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement 2. Disconnect the wiring harness assembly from the fluid temperature sensor (391). 3. Remove the fluid temperature sensor (391). Installation Procedure 1. Install the fluid temperature sensor (391). 2. Connect the wiring harness assembly to the with fluid temperature sensor (391). 3. Install the case side cover. Refer to Case Side Cover Replacement Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Locations > Component Locations Power Window Lockout Switch: Component Locations In the LF door, part of the master window switch. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Locations > Component Locations > Page 2104 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations Power Window Switch: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 2109 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 2110 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 2111 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 2112 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 2113 Power Window Switch: Connector Locations Locations View Window Switch Connector Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 2114 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 2115 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 2116 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 2117 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2120 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2121 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2122 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2123 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2124 Power Window Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2125 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2126 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2127 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2128 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2129 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2130 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2131 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2132 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2133 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2134 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2135 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2136 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2137 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2138 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2139 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2140 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2141 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2142 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2143 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2144 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2145 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2146 Power Window Switch: Connector Views Window Switch, LF, C1 (4 Door) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2147 Window Switch, LF, C2 (2 Door) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2148 Window Switch, LF, C2 (4 Door) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement Power Window Switch: Service and Repair Front Side Door Window Switch Replacement Front Side Door Window Switch Replacement (Impala) Removal Procedure 1. Remove the front door pull cup screws (1) and pull cup from the front door trim panel. Armrest Pull Cup Replacement (Impala) (See: Body and Frame/Interior Moulding / Trim/Arm Rest/Service and Repair/Removal and Replacement/Armrest Pull Cup Replacement). 2. Disconnect the electrical connectors from the front door power window control switch. 3. Remove the front door window control switch using a small, flat-bladed tool at the side of the switch. Installation Procedure 1. Install the front door power window control switch to the front door pull cup pressing into place until fully seated. 2. Connect the electrical connector to the power window control switch. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement > Page 2151 3. Install the front door pull cup and screws (1) to the front door trim panel. Armrest Pull Cup Replacement (Impala) (See: Body and Frame/Interior Moulding / Trim/Arm Rest/Service and Repair/Removal and Replacement/Armrest Pull Cup Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement > Page 2152 Power Window Switch: Service and Repair Power Window Switch Replacement REMOVAL PROCEDURE 1. Remove the front door pull cup from the front door trim panel. Armrest Pull Cup Replacement (Impala). 2. Disconnect the electrical connectors from the front door power window control switch. 3. Remove the front door window control switch from the front door pull cup using a small flat-bladed tool at the side of the power window control switch in order to release the front door power window control switch retainer. INSTALLATION PROCEDURE 1. Install the front door power window control switch to the front door pull cup pressing into place until fully seated. 2. Connect the electrical connectors to the front door power window control switch. 3. Install the front door pull cup to the front door trim panel. Armrest Pull Cup Replacement (Impala). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement > Page 2153 Power Window Switch: Service and Repair Rear Door Power Window Switch Replacement REMOVAL PROCEDURE 1. Remove the rear door pull cup from the rear door trim panel. 2. Disconnect the electrical connectors from the power window control switch. 3. Remove the rear door window control switch from the front door pull cup using a small flat-bladed tool at the side of the power window control switch in order to release the power window control switch retainer. 4. Remove the power window control switch from the rear door pull cup. INSTALLATION PROCEDURE 1. Install the rear door power window control switch to the rear door pull cup pressing into place until fully seated. 2. Connect the electrical connectors to the rear door power window control switch. 3. Install the rear door pull cup to the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Turn Signal Switch, Headlamp Dimmer Switch, Wiper/Washer Switch Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Turn Signal Switch, Headlamp Dimmer Switch, Wiper/Washer Switch > Page 2162 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Turn Signal Switch, Headlamp Dimmer Switch, Wiper/Washer Switch > Page 2163 Windshield Washer Switch: Locations Windshield Wiper/Washer Switch On the multifunction switch. On the RH side of the steering column. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Turn Signal Switch, Headlamp Dimmer Switch, Wiper/Washer Switch > Page 2164 Windshield Washer Switch: Locations Windshield Washer Solvent Level Switch LF of the inner fender well, In the washer reservoir. RF of the inner fender well, In the washer reservoir. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2167 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2168 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2169 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2170 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2171 Windshield Washer Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2172 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2173 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2174 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2175 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2176 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2177 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2178 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2179 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2180 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2181 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2182 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2183 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2184 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2185 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2186 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2187 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2188 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2189 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2190 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2191 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2192 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2193 Windshield Washer Solvent Level Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2194 Wiper/Washer System (Pulse) Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Windshield Wiper Switch Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Windshield Wiper Switch > Page 2199 Wiper Switch: Locations Windshield Wiper/Washer Switch On the multifunction switch. On the RH side of the steering column. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Windshield Wiper Switch > Page 2200 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions Wiper Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2203 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2204 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2205 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2206 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2207 Wiper Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2208 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2209 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2210 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2211 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2212 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2213 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2214 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2215 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2216 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2217 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2218 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2219 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2220 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2221 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2222 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2223 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2224 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2225 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2226 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2227 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2228 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2229 Wiper/Washer System (Pulse) Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2235 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2236 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2237 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2238 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2239 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2240 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2241 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Wheel Alignment Specifications Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Wheel Alignment Specifications > Page 2244 Alignment: Specifications Ride/Trim Height Specifications Trim Height Specifications Measuring Z Height Measuring D Height Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Wheel Alignment Specifications > Page 2245 Measuring J or K Height Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Wheel Alignment Specifications > Page 2246 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber Description Alignment: Description and Operation Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, as shown, the camber is positive (+). When the wheels tilt inward, the camber is negative (-). The amount of tilt measured in degrees from the vertical is known as the camber angle. Camber influences both directional control and tire wear. Excessive camber results in tire wear and causes the vehicle to pull or lead to the side with the most positive camber. Camber adjustment is available at both the front and the rear wheels. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber Description > Page 2249 Alignment: Description and Operation Caster Description Caster is the tilting of the uppermost point of the steering axis, either forward or backward from the vertical, when viewed from the side of the vehicle. A backward tilt at the top is positive (+) and a forward tilt is negative (-). Caster influences the directional control of the steering, but caster does not affect tire wear. One wheel with more positive caster than the other wheel causes that wheel to pull toward the center of the vehicle. The vehicle will move or lead toward that side with the least amount of positive caster. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber Description > Page 2250 Alignment: Description and Operation Toe Description Toe-in is the turning-in of the wheels, while toe-out is the turning-out of the wheels from the geometric centerline/thrust line. The purpose of toe is to ensure parallel rolling of the wheels. Toe also serves to offset the small deflections of the wheel support system which occur whenever the vehicle is rolling forward. Even when the wheels are set to toe-in or toe-out, the wheels tend to roll parallel on the road when the vehicle is moving. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber Description > Page 2251 Alignment: Description and Operation Thrust Angle Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle. The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line off center. The resulting deviation (3) from the centerline is the thrust angle (1). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber Description > Page 2252 Alignment: Description and Operation Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, as shown, the camber is positive (+). When the wheels tilt inward, the camber is negative (-). The amount of tilt measured in degrees from the vertical is known as the camber angle. Camber influences both directional control and tire wear. Excessive camber results in tire wear and causes the vehicle to pull or lead to the side with the most positive camber. Camber adjustment is available at both the front and the rear wheels. Caster Description Caster is the tilting of the uppermost point of the steering axis, either forward or backward from the vertical, when viewed from the side of the vehicle. A backward tilt at the top is positive (+) and a forward tilt is negative (-). Caster influences the directional control of the steering, but caster does not affect tire wear. One wheel with more positive caster than the other wheel causes that wheel to pull toward the center of the vehicle. The vehicle will move or lead toward that side with the least amount of positive caster. Toe Description Toe-in is the turning-in of the wheels, while toe-out is the turning-out of the wheels from the geometric centerline/thrust line. The purpose of toe is to Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber Description > Page 2253 ensure parallel rolling of the wheels. Toe also serves to offset the small deflections of the wheel support system which occur whenever the vehicle is rolling forward. Even when the wheels are set to toe-in or toe-out, the wheels tend to roll parallel on the road when the vehicle is moving. Thrust Angle Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle. The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line off center. The resulting deviation (3) from the centerline is the thrust angle (1). Frame Misalignment Description The frame is a rubber isolated sub-frame in the front of the vehicle. The frame supports the engine and the transaxle. The frame provides the mounting point for the front suspension lower control arms. The frame in the upper illustration is normal. Any misalignment of the frame, as shown, causes a misalignment of the front wheels. Movement of the frame usually causes an increase in caster on one side of the vehicle and a decrease in caster on the other side of the vehicle. This can cause the following conditions: Cause the exhaust system to bind up - Cause problems with the control cables - Cause unacceptable noises and/or sounds Check the frame for any obvious damage. In the illustration, the frame (1) is moved toward the rear. The left lower control arm and the left ball joint are moved toward the rear, changing the caster on the left side only. The top of the strut cannot move because the strut is mounted to the strut tower in the body. General Description Wheel alignment refers to the angular relationship between the following: The wheels - The suspension attaching parts - The ground Four Wheel Alignment Perform a complete wheel alignment check whenever a service check is deemed necessary. This check includes the measurement of all four wheels. The fuel economy and the tire life increases when the vehicle is geometrically aligned. Additionally, the steering and the performance maximize. Lead/Pull Description Lead is the deviation of the vehicle from a straight path on a level road, without hand pressure on the steering wheel. Lead is usually the result of one of the following conditions: 1. Tire construction. Refer to Vibration Diagnosis and Correction under Steering and Suspension Testing and Inspection. Refer also to General Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber Description > Page 2254 Description in Wheels, Tires and Alignment. 2. Uneven parking brake adjustment. Refer to Park Brake Cable Service/Adjustment in Brakes. 3. Wheel Alignment The way in which a tire is built may produce lead. Rear tires do not cause lead. Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel spindle may be aligned behind the other wheel spindle. In the illustration, the left side frame (1) is moved toward the rear, causing a misalignment. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than one degree. Torque Steer Description A vehicle pulls or leads in one direction during hard acceleration. A vehicle pulls or leads in the other direction during deceleration. The following factors may cause torque steer to be more apparent on a particular vehicle: A slightly smaller diameter tire on the right front increases a right torque lead. Inspect the front tires for differences in the brand, the construction, or the size. If the tires appear to be similar, change the front tires from side-to-side and retest the vehicle. Tire and wheel assemblies have the most significant effect on torque steer correction. - A large difference in the right and left front tire pressure - Left-to-right differences in the front view axle angle may cause significant steering pull in a vehicle. The pull will be to the side with the most downward sloping axle from the differential to the wheels. Axles typically slope downward from the differential. The slope of the transaxle pan to level ground may be used as an indication of bias axle angles. The side with the higher transaxle pan (shown on the left side of the illustration) has the most downward sloping axle angle. Wander Description Wander is the undesirable drifting or deviation of a vehicle toward either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of a vehicle's sensitivity to external disturbances, such as road crown and crosswind. A poor, on-center steering feel accentuates a wander condition. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Alignment Inspection Alignment: Service and Repair Preliminary Alignment Inspection Loose and worn suspension parts prevents an accurate setting of alignment angles. Before you make any alignment adjustments, ensure the correctness of the alignment readings and the adjustments: Check the tires for proper inflation pressures. Refer to Tire Inflation Pressure Specifications. - Check the tires for normal tread wear. - Check the hub and bearing for excessive wear. - Check the ball joints and the tie rods for looseness. - Inspect the wheels and tires for runout, resulting from bent wheels or faulty tires. - Inspect vehicle trim heights. If the trim heights are not within specifications, make necessary corrections before adjusting the alignment. Refer to Trim Height Specifications in Suspension General Diagnosis. - Check the steering gear for looseness at the frame. - Check the struts for improper operation. - Inspect the control arms for loose or worn bushings. - Check the stabilizer shaft attachments for loose or missing components. - Check the alignment pins for improper frame alignment to the body. - Check the frame fasteners for proper torque. - Check the frame insulators for wear or damage. Before checking the alignment, become familiar with the instructions that are furnished by the equipment manufacturer. Methods will vary with different equipment. Regardless of the equipment used for adjusting the alignment, always keep the vehicle on a level surface, both fore-and-aft and sideways. Important: - Check and set the alignment with a full fuel tank. - Jounce the vehicle three times before you check the alignment in order to eliminate false readings. - Hold the front and the rear suspensions to the specified dimensions. Refer to Trim Height Specifications in Suspension General Diagnosis. - Set the toe left side adjustment and the toe right side adjustment separately per wheel. Hold the steering wheel level at O degrees plus or minus 3.5 degrees. Cross caster within 0.75 degrees. - Cross camber within 0.75 degrees. Adjust Perform four wheel alignment adjustments in the following order: 1. Rear wheel camber 2. Rear wheel toe and tracking 3. Front wheel camber 4. Front wheel toe and steering wheel angle Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Alignment Inspection > Page 2257 Alignment: Service and Repair Pre-Alignment Road Test With Customer Perform a road test on the vehicle with the customer. The road test may help to identify many faulty parts: - Worn control arm bushings or strut bearings - Weak strut dampeners - Loose power steering gear mounts - Wheel bearings - Tires Obvious conditions must be brought to the customer's attention before beginning an alignment. A waddle feeling in the back of the vehicle often indicates the occurrence of a bent rim and/or a belt shift in one of the rear tires. Vibration in the steering wheel or in the floor pan is often the result of static imbalance or radial runout of the front tires. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Alignment Inspection > Page 2258 Alignment: Service and Repair Measuring Wheel Alignment Important: This vehicle requires a four wheel alignment. Set the rear wheel alignment angles first to obtain proper front alignment angles. 1. Following the manufacturer's instructions to install alignment equipment. 2. Prior to checking alignment perform the following actions: - Jounce the front bumper 3 times - Jounce the rear bumper 3 times 3. Measure and record the alignment angles. Refer to Wheel Alignment Specifications (Front) or Wheel Alignment Specifications (Rear). Important: When making adjustments to the vehicle set the left side to specifications first. Use the actual readings on the left side as targets for the right side to achieve a minimal cross variance. 4. Make the adjustments that are necessary. 5. Check toe AFTER changing Camber. 6. Check for damaged suspension members if proper specifications cannot be obtained. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Alignment Inspection > Page 2259 Alignment: Service and Repair Front Wheel Alignment Front Camber Adjustment Removal Procedure 1. Raise the vehicle and provide suitable support. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies from the front and the rear axles. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Remove the strut from the vehicle. Refer to Strut Assembly Replacement in Steering and Suspension. 4. Place the strut in a vise and file the hole lateral (oblong). Compare the appearance of the holes before filing (2) with after filing (3): Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the strut to the vehicle. Refer to Strut Assembly Replacement in Steering and Suspension. Tighten the strut-to-knuckle bolts as far as to allow movement of the knuckle. 2. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Adjust the camber (1). Tighten the strut-to-knuckle bolts to 122 Nm (90 ft. lbs.) Lower the vehicle. Front Wheel Toe Adjustment 1. Perform the following steps to remove the small seal clamp: 2. Position the steering wheel in the straight ahead position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Alignment Inspection > Page 2260 3. Loosen the hex nut on the tie rod (2). Turn the tie rod shaft (1) in order to obtain the proper toe angle. Refer to Wheel Alignment Specifications (Front) or Wheel Alignment Specifications (Rear). 4. Confirm the number of threads showing on each tie rod end is nearly equal. Notice: Refer to Fastener Notice in Service Precautions. 5. Confirm that the tie rod ends (3) are square before you tighten the lock nuts (2). Tighten the hex nuts at the tie rod ends to 68 Nm (50 ft. lbs.). Important: Ensure the seals do not twist. 6. Install the seal clamps. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Alignment Inspection > Page 2261 Alignment: Service and Repair Preliminary Alignment Inspection Loose and worn suspension parts prevents an accurate setting of alignment angles. Before you make any alignment adjustments, ensure the correctness of the alignment readings and the adjustments: Check the tires for proper inflation pressures. Refer to Tire Inflation Pressure Specifications. - Check the tires for normal tread wear. - Check the hub and bearing for excessive wear. - Check the ball joints and the tie rods for looseness. - Inspect the wheels and tires for runout, resulting from bent wheels or faulty tires. - Inspect vehicle trim heights. If the trim heights are not within specifications, make necessary corrections before adjusting the alignment. Refer to Trim Height Specifications in Suspension General Diagnosis. - Check the steering gear for looseness at the frame. - Check the struts for improper operation. - Inspect the control arms for loose or worn bushings. - Check the stabilizer shaft attachments for loose or missing components. - Check the alignment pins for improper frame alignment to the body. - Check the frame fasteners for proper torque. - Check the frame insulators for wear or damage. Before checking the alignment, become familiar with the instructions that are furnished by the equipment manufacturer. Methods will vary with different equipment. Regardless of the equipment used for adjusting the alignment, always keep the vehicle on a level surface, both fore-and-aft and sideways. Important: - Check and set the alignment with a full fuel tank. - Jounce the vehicle three times before you check the alignment in order to eliminate false readings. - Hold the front and the rear suspensions to the specified dimensions. Refer to Trim Height Specifications in Suspension General Diagnosis. - Set the toe left side adjustment and the toe right side adjustment separately per wheel. Hold the steering wheel level at O degrees plus or minus 3.5 degrees. Cross caster within 0.75 degrees. - Cross camber within 0.75 degrees. Adjust Perform four wheel alignment adjustments in the following order: 1. Rear wheel camber 2. Rear wheel toe and tracking 3. Front wheel camber 4. Front wheel toe and steering wheel angle Pre-Alignment Road Test With Customer Perform a road test on the vehicle with the customer. The road test may help to identify many faulty parts: - Worn control arm bushings or strut bearings - Weak strut dampeners - Loose power steering gear mounts - Wheel bearings - Tires Obvious conditions must be brought to the customer's attention before beginning an alignment. A waddle feeling in the back of the vehicle often indicates the occurrence of a bent rim and/or a belt shift in one of the rear tires. Vibration in the steering wheel or in the floor pan is often the result of static imbalance or radial runout of the front tires. Measuring Wheel Alignment Important: This vehicle requires a four wheel alignment. Set the rear wheel alignment angles first to obtain proper front alignment angles. 1. Following the manufacturer's instructions to install alignment equipment. 2. Prior to checking alignment perform the following actions: - Jounce the front bumper 3 times - Jounce the rear bumper 3 times 3. Measure and record the alignment angles. Refer to Wheel Alignment Specifications (Front) or Wheel Alignment Specifications (Rear). Important: When making adjustments to the vehicle set the left side to specifications first. Use the actual readings on the left side as targets for the right side to achieve a minimal cross variance. 4. Make the adjustments that are necessary. 5. Check toe AFTER changing Camber. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Alignment Inspection > Page 2262 6. Check for damaged suspension members if proper specifications cannot be obtained. Front Camber Adjustment Removal Procedure 1. Raise the vehicle and provide suitable support. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies from the front and the rear axles. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Remove the strut from the vehicle. Refer to Strut Assembly Replacement in Steering and Suspension. 4. Place the strut in a vise and file the hole lateral (oblong). Compare the appearance of the holes before filing (2) with after filing (3): Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the strut to the vehicle. Refer to Strut Assembly Replacement in Steering and Suspension. Tighten the strut-to-knuckle bolts as far as to allow movement of the knuckle. 2. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Adjust the camber (1). Tighten the strut-to-knuckle bolts to 122 Nm (90 ft. lbs.) Lower the vehicle. Front Wheel Toe Adjustment 1. Perform the following steps to remove the small seal clamp: 2. Position the steering wheel in the straight ahead position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Alignment Inspection > Page 2263 3. Loosen the hex nut on the tie rod (2). Turn the tie rod shaft (1) in order to obtain the proper toe angle. Refer to Wheel Alignment Specifications (Front) or Wheel Alignment Specifications (Rear). 4. Confirm the number of threads showing on each tie rod end is nearly equal. Notice: Refer to Fastener Notice in Service Precautions. 5. Confirm that the tie rod ends (3) are square before you tighten the lock nuts (2). Tighten the hex nuts at the tie rod ends to 68 Nm (50 ft. lbs.). Important: Ensure the seals do not twist. 6. Install the seal clamps. Rear Camber Adjustment Removal Procedure 1. Raise the vehicle and provide suitable support. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Remove the strut from the vehicle. Refer to Strut Assembly Replacement in Rear Suspension. 4. Place the strut in a vise and file the upper strut-to-knuckle hole lateral (oblong). Compare the appearance of the holes before filing (2) with after filing (3). Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the strut to the vehicle. Refer to Strut Assembly Replacement in Rear Suspension. Tighten the strut-to-knuckle bolts as far as to allow movement of the knuckle. 2. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Alignment Inspection > Page 2264 3. Adjust the camber (1). Tighten the strut-to-knuckle bolts to 122 Nm (90 ft. lbs.) 4. Lower the vehicle. Rear Toe Adjustment 1. Loosen the hex nuts at the rear wheel spindle rod (rear). 2. Turn the adjusting nut to change the toe angle. 3. Adjust the toe to the proper setting. Refer to Wheel Alignment Specifications (Front) or Wheel Alignment Specifications (Rear). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Alignment Inspection > Page 2265 4. Tighten the hex nuts on the rear wheel spindle rod (rear). Tighten the rear wheel spindle rod ends hex nuts to 50 Nm (37 ft. lbs.). Alignment Rack Maintenance Adjust the rack for level and for calibration according to the manufacturer's recommended intervals. Refer to the alignment rack manufacturer's operators guide for information regarding the adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure - Correct Operating Range Fuel Pressure: Technical Service Bulletins Fuel Pressure - Correct Operating Range File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-018 Date: May, 1999 INFORMATION Subject: Correct Fuel Pressure Operating Range Models: 2000 Buick Century 2000 Chevrolet Impala, Lumina, Malibu, Monte Carlo, Venture 2000 Oldsmobile Alero, Silhouette 2000 Pontiac Grand Am, Grand Prix, Montana with 3.1 L or 3.4 L V6 Engine (VINs J, E - RPOs LG8, LA1) All 2000 model year 3.1 L and 3.4 L engines have a revised fuel pressure regulator and Multec II fuel injectors. The fuel system operating pressure is 358-405 kPa (52-59 psi) on these applications. Important: ^ This regulator is NOT interchangeable with past model applications. When replacement is necessary for the above listed applications, use only regulator P/N 17113622. ^ Installing regulators other than the above listed part number in these applications may result in a change in engine performance and/or driveability concerns. Refer to the Engine Controls subsection of the Service Manual for complete diagnostic and repair information on fuel system related concerns. Parts Information Part Number Description 17113622 Fuel Pressure Regulator Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 2271 Fuel Pressure: Specifications Fuel Pressure Fuel Pressure Fuel Pressure 52-59 psi Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis Fuel Pressure: Testing and Inspection Fuel System Diagnosis Diagnostic Chart (Part 1 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 2274 Diagnostic Chart (Part 2 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 2275 Diagnostic Chart (Part 3 Of 3) SYSTEM DESCRIPTION Proper fuel pressure is necessary to maintain efficient engine operation and emission levels, if fuel pressure is not within specifications vehicle driveablity may be affected or emission levels elevated. The fuel system contains the following components: ^ Fuel strainer ^ Modular fuel sender assembly ^ Fuel filter ^ Fuel feed pipes and hoses ^ Fuel pressure regulator ^ Fuel rail ^ Fuel injectors ^ Fuel return pipes and hoses TEST DESCRIPTION The numbers below refer to the step numbers on the diagnostic table. 2. Tests the fuel systems ability to achieve a specific fuel pressure range. It may be necessary to cycle the fuel pump several times to achieve the pressure range. 6. A fuel system that drops more than 5 psi in 10 minutes has a leak in one or more areas. 8. Tests the fuel systems ability to maintain a specific fuel pressure. It may be necessary to cycle the fuel pump several times to achieve the pressure range. 9. Fuel pressure that drops-off during acceleration, cruise, or hard cornering may cause a lean condition. A lean condition can cause a loss of power, surging, or misfire and may be diagnosed using a scan tool. If an extremely lean condition occurs, the oxygen sensors may drop below 500 mV and the fuel injector pulse width will increase. 13. When the engine is at idle, the manifold pressure is low, high vacuum. This low pressure, high vacuum, is applied to the fuel pressure regulator diaphragm, the result is lower fuel pressure. The fuel pressure at idle will vary slightly as the pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in Step 2 with the engine OFF. 14. This test determines if the high fuel pressure is due to a restricted fuel return pipe or fuel pressure regulator. A rich condition may cause a DTC P0132 or DTC P0172 to set. Driveability conditions associated with rich conditions can include hard starting, followed by black smoke, and a Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 2276 strong sulfur smell in the exhaust. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 2277 Fuel Pressure: Testing and Inspection Fuel System Pressure Test Diagnostic Chart (Part 1 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 2278 Diagnostic Chart (Part 2 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 2279 Diagnostic Chart (Part 3 Of 3) SYSTEM DESCRIPTION Proper fuel pressure is necessary to maintain efficient engine operation and emission levels, if fuel pressure is not within specifications vehicle driveablity may be affected or emission levels elevated. The fuel system contains the following components: ^ Fuel strainer ^ Modular fuel sender assembly ^ Fuel filter ^ Fuel feed pipes and hoses ^ Fuel pressure regulator ^ Fuel rail ^ Fuel injectors ^ Fuel return pipes and hoses TEST DESCRIPTION The numbers below refer to the step numbers on the diagnostic table. 2. Tests the fuel systems ability to achieve a specific fuel pressure range. It may be necessary to cycle the fuel pump several times to achieve the pressure range. 6. A fuel system that drops more than 5 psi in 10 minutes has a leak in one or more areas. 8. Tests the fuel systems ability to maintain a specific fuel pressure. It may be necessary to cycle the fuel pump several times to achieve the pressure range. 9. Fuel pressure that drops-off during acceleration, cruise, or hard cornering may cause a lean condition. A lean condition can cause a loss of power, surging, or misfire and may be diagnosed using a scan tool. If an extremely lean condition occurs, the oxygen sensors may drop below 500 mV and the fuel injector pulse width will increase. 13. When the engine is at idle, the manifold pressure is low, high vacuum. This low pressure, high vacuum, is applied to the fuel pressure regulator diaphragm, the result is lower fuel pressure. The fuel pressure at idle will vary slightly as the pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in Step 2 with the engine OFF. 14. This test determines if the high fuel pressure is due to a restricted fuel return pipe or fuel pressure regulator. A rich condition may cause a DTC P0132 or DTC P0172 to set. Driveability conditions associated with rich conditions can include hard starting, followed by black smoke, and a Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 2280 strong sulfur smell in the exhaust. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2284 Idle Speed: Adjustments The Powertrain Control Module (PCM) controls engine idle speed by adjusting the position of the Idle Air Control (IAC) motor pintle. The IAC is a bi-directional motor driven by two coils. The PCM pulses current to the IAC coils in steps, counts, to extend the IAC pintle into a passage in the throttle body to decrease air flow. The PCM reverses the current pulses to retract the pintle, increasing air flow. This method allows highly accurate control of idle speed and quick response to changes in engine load. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2294 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2300 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2301 Air Filter Element: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the IAT sensor electrical connector. 3. Disconnect the breather tube from the air intake duct. 4. Disconnect the MAF sensor electrical connector. 5. Loosen the air intake duct/MAF sensor hose clamps. 6. Carefully remove the air inlet hose from the throttle body and air cleaner cover. 7. Remove the 2 housing cover retaining clamps. 8, Remove the air cleaner cover (5) and carefully remove the air filter element (6). 9. Inspect the housing cover (5), seal assembly, and air ducting (2) for damage. INSTALLATION PROCEDURE 1. Carefully install the air filter element (6) into the air cleaner assembly (1). 2. Install the housing cover (5) and install the housing cover retaining screws (2). 3. Carefully install the air inlet hose to the throttle body and air cleaner cover. 4. Tighten the air inlet hose clamp. 5. Install the air intake duct/MAF sensor assembly. 6. Tighten the air intake duct/MAF sensor hose clamps. 7. Connect the breather tube to the air intake duct. 8, Connect the MAF sensor electrical connector. 9. Connect the IAT sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair RELIEF PROCEDURE Tools Required ^ J34730-1A Fuel Pressure Gauge ^ J34730-262 Fuel Pressure Gauge Fitting CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery terminal. IMPORTANT: Mount the fuel pressure gauge fitting below the belt to avoid contact with the belt. 2. Install the J 34730-262 fuel pressure gauge fitting adaptor to the fuel pressure connection. 3. Connect fuel pressure gauge J 34730-1A to the fuel gauge pressure fitting. Wrap a shop towel around the fuel pressure connection while connecting the fuel pressure gauge in order to avoid spillage. 4. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the fuel pressure gauge into an approved container. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations > Page 2309 Ignition Cable: Service Precautions NOTE: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations > Page 2310 Ignition Cable: Service and Repair REMOVAL PROCEDURE 1. Turn the ignition switch to the OFF position. 2. Note the position of the spark plug wire retaining clips. Remove the spark plug wire retaining clips from the engine. NOTE: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged. 3. Note the position of the spark plug wire(s). Remove the spark plug wires (2,4,6) from the front spark plugs by twisting the boot 1/2 turn before removing the spark plug boot(s). 4. Note the position of the spark plug wire(s). Remove the spark plug wires (1,3,5) from the rear spark plugs by twisting the boot 1/2 turn before removing the spark plug boot(s). 5. Remove the spark plug wire retaining clips from the rear of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations > Page 2311 6. Remove the spark plug wires from the ignition coils. 7. Remove the spark plug wires from the engine. 8. If replacing the spark plug wires, transfer any of the following: ^ Boot heat shields ^ Spark plug wire conduit ^ Spark plug wire retaining clips INSTALLATION PROCEDURE 1. Position the spark plug wire(s) to the engine. 2. Install the spark plug wires to the ignition coils in the proper position. 3. Install the spark plug wires (1,3,5) to the rear spark plugs. 4. Install the spark plug wire retaining clips from the rear of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations > Page 2312 5. Install the spark plug wire (2,4,6) to the front spark plugs. 6. Install the spark plug wire retaining clips to the front of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug Usage Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Spark Plug Service Precautions Spark Plug: Service Precautions Spark Plug Service Precautions NOTE: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged. NOTE: Observe the following service precautions: ^ Allow the engine to cool before removing the spark plugs. Attempting to remove spark plugs from a hot engine can cause the spark plugs to seize. This can damage the cylinder head threads. ^ Clean the spark plug recess area before removing the spark plug. Failure to do so can result in engine damage due to dirt or foreign material entering the cylinder head, or in contamination of the cylinder head threads. Contaminated threads may prevent proper seating of the new spark plug. ^ Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the vehicle. Installing spark plugs of another type can severely damage the engine. NOTE: ^ It is important to check the gap of all new and reconditioned spark plugs before installation. Pre-set gaps may have changed during handling. Use a round wire feeler gauge to be sure of an accurate check, particularly on used plugs. Installing plugs with the wrong gap can cause poor engine performance and may even damage the engine. ^ Be sure plug threads smoothly into cylinder head and is fully seated. Use a thread chaser if necessary to clean threads in cylinder head. Cross-threading or failing to fully seat spark plug can cause overheating of plug, exhaust blow-by, or thread damage. Follow the recommended torque specifications carefully. Over or under-tightening can also cause severe damage to engine or spark plug. NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Spark Plug Service Precautions > Page 2318 Spark Plug: Service Precautions Platinum Tip Spark Plug Maintenance Information Platinum Tip Spark Plug Maintenance Information for all 95-02 Models Equipped with Platinum Tip Spark Plugs The following information was originally sent to all General Motors dealers as a DCS message on October 14, 1999. Recommendation / Instructions: It has come to our attention that some GM dealers sell a customer service to remove platinum tipped spark plugs and clean the threads at regular intervals to prevent the seizure of the spark plugs in the cylinder heads at high mileage. Platinum tipped spark plugs are designed to operate under normal vehicle operating conditions for up to 100,000 miles (160,000 kms) without periodic maintenance. When no engine performance concerns are present, platinum tipped spark plugs should not be removed for periodic inspection and cleaning of threads, doing so would compromise the spark plugs ability to withstand their corrosive environment. The threaded area, although not sealed, serves as a protective environment against most harmful elements. Removing and cleaning spark plugs will introduce metallic debris and brush scrapings into the thread area which may further the corrosion process. Chromate coated spark plugs should not be wire brushed or handled in any way once they are put in service. Chromium topcoats form a protective oxide on spark plugs that is not effective if scratched. Both coated and uncoated spark plugs will have the best chance of surviving a corrosive environment if they are left in position. Attempts to maintain spark plugs by removing them and cleaning the threads can actually create the corrosive condition that the procedure was intended to prevent. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Page 2319 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ........................................................ AC Type 41-940 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Page 2320 Spark Plug: Description and Operation Worn, cracked or dirty plugs may give satisfactory operation at idling speed, but under operating conditions they frequently fail. Faulty plugs are indicated in a number of ways: poor fuel economy, loss of power and speed, hesitation, shudder, medium throttle intake manifold backfire, hard starting and general poor engine performance. Fouled plugs may be indicated by black carbon deposits. The black deposits are usually the result of slow-speed driving and short runs where sufficient engine operating temperature is seldom reached. Worn pistons, rings, faulty ignition, over-rich fuel mixture or low heat range spark plugs may result in carbon deposits. Excessive gap wear on plugs of low mileage, usually indicates the engine is operating at high speeds or loads that are consistently greater than normal or that a plug which is too hot of a heat range is being used. Electrode wear may also be the result of plug overheating, caused by combustion gases leaking past the threads, due to insufficient torque of the spark plug. Excessively lean fuel mixture will also result in excessive electrode wear. Broken insulators are usually the result of improper installation or carelessness when gapping the plug. Broken upper insulators usually result from a poor fitting wrench or an outside blow. The cracked insulator may not show up right away, but will as soon as oil or moisture penetrates the crack. The crack is usually just below the crimped part of shell and may not be visible. Broken lower insulators usually result from carelessness when gapping and generally are visible. This type of break may result from the plug operating too Hot, which may happen in periods of high-speed operation or under heavy loads. When gapping a spark plug, always make the gap adjustment by bending the ground (side) electrode. Spark plugs with broken insulators should always be replaced. Each spark plug boot covers the spark plug terminal and a portion of the plug insulator. These boots prevent flash-overwhich causes engine misfiring. Do not mistake corona discharge for flash-over or a shorted insulator. Corona is a steady blue light appearing around the insulator, just above the shell crimp. It is the visible evidence of high-tension field and has no effect on ignition performance. Usually it can be dust particles leaving a clear ring on the insulator just above the shell. This ring is sometimes mistakenly regarded as evidence that combustion gases have blown out between shell and insulator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Page 2321 Spark Plug: Testing and Inspection Normal spark plug operation will result in brown to grayish-tan deposits appearing on the portion of the spark plug that projects into the cylinder area. A small amount of red-brown, yellow, and white powdery material may also be present on the insulator tip around the center electrode. These deposits are normal combustion by-products of fuels and lubricating oils with additives. Some electrode wear will also occur. Engines which are not running properly are often referred to as misfiring. Spark plug misfiring can be indicated in a number of ways: ^ Poor fuel economy ^ Power loss ^ Loss of speed ^ Hard starting ^ Poor engine performance Flashover occurs when a damaged spark plug boot, along with dirt and moisture, permits the high voltage charge to short over the insulator to the spark plug shell or the engine. Should misfiring occur before the recommended replacement interval, locate and correct the cause. Carbon fouling of the spark plug is indicated by dry, black carbon (soot) deposits on the portion of the spark plug in the cylinder. Excessive idling or slow speeds under light engine loads can keep the spark plug temperatures so low that these deposits are not burned off. Rich fuel mixtures or poor ignition system output may also be the cause. Oil fouling of the spark plug is indicated by wet oily deposits on the portion of the spark plug in the cylinder, usually with little electrode wear. This may be caused by oil getting past worn piston rings or valve seals. This condition also may occur during break-in of new or newly overhauled engines. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Page 2322 Deposit fouling of the spark plug occurs when the normal red-brown, yellow or white deposits of combustion by-products become sufficient to cause misfiring. In some cases, these deposits may melt and form a shiny glaze on the insulator around the center electrode. If the fouling is found in only one or two cylinders, valve stem clearances or intake valve seals may be allowing excess lubricating oil to enter the cylinder, particularly if the deposits are heavier on the side of the spark plug that was facing the intake valve. Excessive gap means that the airspace between the center and side electrodes at the bottom of the spark plug is too wide for consistent spark plug firing. This may be due to improper gap adjustment or to excessive wear of the electrodes during use. Check of the gap size and compare the gap measurement to that specified for the vehicle. Excessive gap wear can be an indication of continuous operation at high speeds or with high engine loads, causing the spark plug to run too hot. Too small of a gap indicates the plug was damaged at the time of installation. Another possible cause is an excessively lean fuel mixture. Low or high spark plug installation torque or improper seating of the spark plug can result in the spark plug running too hot and cause excessive gap wear. The spark plug and cylinder head seats must be in good contact for proper heat transfer and spark plug cooling. Dirty or damaged threads in the head or on the spark plug can keep the spark plug from seating even though the proper torque is applied. Once the spark plugs are properly seated, tighten the spark plug to the proper torque. Low torque may result in poor contact of seats due to a loose spark plug. Overtightening may cause the spark plug shell to be stretched and also result in poor contact between seats. In extreme cases, exhaust blow-by and damage beyond simple gap wear may occur. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Page 2323 Cracked or broken insulators may be the result of improper installation, damage during spark plug regapping, or heat shock to the insulator material. Upper insulators can be broken when a poorly fitting tool is used during installation or removal, or when the spark plug is hit from the outside. Cracks in the upper insulator may be inside the shell and not visible. Also, the breakage may not cause problems until oil or moisture penetrates the crack later. A broken or cracked lower insulator tip (around the center electrode) can result from damage during regapping or from heat shock (spark plug suddenly operating too hot). Damage during regapping can happen if the gapping tool is pushed against the center electrode or the insulator around it, causing the insulator to crack. When regapping a spark plug, make the adjustment by only bending the side electrode. Do not contact other parts. Heat shock breakage in the lower insulator tip generally occurs during severe engine operating conditions (high-speeds or heavy-loading) and may be caused by over advanced timing or low grade fuels. Heat shock refers to a rapid increase in the tip temperature that causes the insulator material to crack. Spark plugs with less than the recommended amount of service can sometimes be cleaned and regapped, then returned to service. However, if there is any doubt about the serviceability of a spark plug, replace it. Replace spark plugs with cracked or broken insulators. In some cases, such as flashover, the ignition wire may need to be changed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Page 2324 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT Removal Procedure Tools Required J38491 Spark Plug Heat Shield Removal Tool 1. Turn OFF the ignition switch. 2. Remove the spark plug wires from the spark plugs. NOTE: ^ Allow the engine to cool before removing the spark plugs. Attempting to remove the spark plugs from a hot engine may cause the plug threads to seize, causing damage to cylinder head threads. ^ Clean the spark plug recess area before removing the spark plug. Failure to do so could result in engine damage because of dirt or foreign material entering the cylinder head, or by the contamination of the cylinder head threads. The contaminated threads may prevent the proper seating of the new plug. Use a thread chaser to clean the threads of any contamination. 3. Remove the spark plugs from the engine. Installation Procedure NOTE: ^ Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the vehicle. Installing spark plugs of another type can severely damage the engine. ^ Check the gap of all new and reconditioned spark plugs before installation. The pre-set gaps may have changed during handling. Use a round feeler gage to ensure an accurate check. Installing the spark plugs with the wrong gap can cause poor engine performance and may even damage the engine. 1. Measure the spark plug gap on the spark plugs to be installed and correct as necessary. Spark Plug Gap: 0.060 in (1.52 mm) NOTE: ^ Be sure that the spark plug threads smoothly into the cylinder head and the spark plug is fully seated. Use a thread chaser, if necessary, to clean threads in the cylinder head. Cross-threading or failing to fully seat the spark plug can cause overheating of the plug, exhaust blow-by, or thread damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Page 2325 2. Install the spark plugs to the engine. Torque: 15 N.m (11 ft. lb.) 3. Connect the spark plug wires to the spark plugs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The lowest reading should not be less than 70 percent of the highest reading. No cylinder reading should be less than 689 kPa (100 psi). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2329 Compression Check: Testing and Inspection A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the head gasket. Important: Remove the Powertrain Control Module (PCM) and the ignition fuses from the I/P fuse block. 1. Disable the ignition. 2. Disable the fuel systems. 3. Remove the spark plugs from all the cylinders. 4. Remove the air duct from the throttle body. 5. Block the throttle plate in the open position. 6. Measure the engine compression, using the following procedure: 6.1. Firmly install the compression gauge to the spark plug hole. 6.2. Have an assistant crank the engine through at least 4 compression strokes in the testing cylinder. 6.3. Record the readings on the gauge at each stroke. 6.4. Disconnect the gauge. 6.5. Repeat the compression test for each cylinder. 7. Record the compression readings from all of the cylinders. - The lowest reading should not be less than 70 percent of the highest reading. - No cylinder reading should be less than 689 kPa (100 psi). 8. The following list is examples of the possible measurements: - When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each cylinder. - When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal compression, the piston rings may be the cause. - If the compression improves considerably with the addition of three squirts of oil, the piston rings may be the cause. - When the compression is low on the first stroke and does not build up in the following strokes, the valves may be the cause. - The addition of oil does not affect the compression, the valves may be the cause. - When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause. 9. Remove the block from the throttle plate. 10. Install the air duct to the throttle body. 11. Install the spark plugs. 12. Install the Powertrain Control Module (PCM) fuse. 13. Install the ignition fuse to the I/P fuse block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2337 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2338 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2339 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 2340 Drive Belt: Specifications Drive Belt Shield Bolt 89 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 2341 Drive Belt: Diagrams Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Notice: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2344 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2345 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2346 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2347 Drive Belt: Testing and Inspection Drive Belt Chirping Notice: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2348 Drive Belt Squeal Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2349 Notice: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 2350 Drive Belt: Service and Repair Removal Procedure Important: After the new drive belt is installed, make sure that the mark on the drive belt tensioner is in range, as indicated on the tensioner housing. 1. Rotate the drive belt tensioner in order to release the pressure on the drive belt. 2. Remove the drive belt. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 2351 1. Install the drive belt to all of the pulleys except the generator pulley. 2. Rotate the drive belt tensioner in order to install the drive belt over the generator pulley. 3. Make sure that the drive belt is properly routed. Important: Make sure the mark on the drive belt tensioner is in range, as indicated on the tensioner housing. 4. Make sure the drive belt tensioner is operating properly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON > Page 2362 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2368 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2369 Air Filter Element: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the IAT sensor electrical connector. 3. Disconnect the breather tube from the air intake duct. 4. Disconnect the MAF sensor electrical connector. 5. Loosen the air intake duct/MAF sensor hose clamps. 6. Carefully remove the air inlet hose from the throttle body and air cleaner cover. 7. Remove the 2 housing cover retaining clamps. 8, Remove the air cleaner cover (5) and carefully remove the air filter element (6). 9. Inspect the housing cover (5), seal assembly, and air ducting (2) for damage. INSTALLATION PROCEDURE 1. Carefully install the air filter element (6) into the air cleaner assembly (1). 2. Install the housing cover (5) and install the housing cover retaining screws (2). 3. Carefully install the air inlet hose to the throttle body and air cleaner cover. 4. Tighten the air inlet hose clamp. 5. Install the air intake duct/MAF sensor assembly. 6. Tighten the air intake duct/MAF sensor hose clamps. 7. Connect the breather tube to the air intake duct. 8, Connect the MAF sensor electrical connector. 9. Connect the IAT sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations > Page 2373 Cabin Air Filter: Description and Operation The filters have a 12 months or 20,000 km (15,000 miles) change interval. These filters may require frequent change intervals depending on driving conditions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations > Page 2374 Cabin Air Filter: Service and Repair PASSENGER COMPARTMENT AIR FILTER REPLACEMENT (IF EQUIPPED) REMOVAL PROCEDURE 1. Position the windshield wipers in the UP position, by keying the ignition OFF when the wiper reach the desired position. 2. Raise the hood. 3. Position aside the rear hood seal halfway to the center. Refer to Seal Replacement - Hood Rear in Body Front End. 4. Remove the right air inlet grill. 5. Remove the passenger compartment air filter. INSTALLATION PROCEDURE 1. Install the passenger compartment air filter. 2. Install the air inlet grill. Refer to Air Inlet Grille Panel Replacement in Body Front End. 3. Install the rear hood seal. 4. Close the hood. 5. Return the windshield wipers to the PARK position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair Removal Procedure 1. Remove the oil pan (24) and the gasket (25). Refer to Oil Pan Replacement. 2. Remove the filter (100). Remove the lip ring seal (101) pressed into the case only if replacement is necessary. 3. Inspect the screen for the following foreign material: - Inspect for metal particles. - Inspect for clutch facing material. - Inspect for rubber particles. - Inspect for engine coolant. 4. Determine the source of the contamination if foreign material is evident. 5. Correct the source of the contamination. 6. Use solvent to clean the screen. 7. Blow-dry the screen. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 2378 1. If removed, install a new seal (101). 2. Install the filter (100), a new filter if required. 3. Install the gasket (25) and the oil pan (24). Refer to Oil Pan Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair RELIEF PROCEDURE Tools Required ^ J34730-1A Fuel Pressure Gauge ^ J34730-262 Fuel Pressure Gauge Fitting CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery terminal. IMPORTANT: Mount the fuel pressure gauge fitting below the belt to avoid contact with the belt. 2. Install the J 34730-262 fuel pressure gauge fitting adaptor to the fuel pressure connection. 3. Connect fuel pressure gauge J 34730-1A to the fuel gauge pressure fitting. Wrap a shop towel around the fuel pressure connection while connecting the fuel pressure gauge in order to avoid spillage. 4. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the fuel pressure gauge into an approved container. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation The fuel pump strainer attaches to the lower end of the modular fuel sender assembly. The fuel pump strainer is made of woven plastic. The functions of the fuel pump strainer is to filter contaminants and to wick fuel. The life of the fuel pump strainer is generally considered to be that of the fuel pump, is self-cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water, in which case the tank should be thoroughly cleaned and replace the plugged fuel pump strainer with a new one. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation > Page 2386 Fuel Pump Pickup Filter: Service and Repair REMOVAL PROCEDURE IMPORTANT: Always maintain cleanliness when servicing fuel system components. Fuel Sender Assembly 1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Remove the fuel sender assembly. 3. Note strainer (3) position for future reference. 4. Support the reservoir with one hand and grasp the strainer with the other hand. 5. Use a screwdriver to pry the strainer ferrule off the reservoir. 6. Discard the strainer. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation > Page 2387 1. Install the new strainer (4) to the reservoir. 2. Support the reservoir with one hand and grasp the strainer with the other hand twisting the strainer into position. 3. Reinstall the fuel sender assembly. 4. Reconnect the negative battery cable. 5. Inspect for fuel leaks. 5.1. Turn the ignition ON for 2 seconds. 5.2. Turn the ignition OFF for 10 seconds. 5.3. Turn the ignition ON. 5.4. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 2392 Oil Filter: Specifications Oil Filter 115 in.lb Oil Filter Bypass Hole Plug 14 ft.lb Oil Filter Fining 29 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 2393 Oil Filter: Service and Repair Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Position the oil drain pan under the engine oil drain plug. 3. Remove the engine oil pan drain plug. 4. Clean and inspect the engine oil pan drain plug, repair or replace if necessary. 5. Clean and inspect the engine oil pan drain plug sealing surface on the oil pan, repair or replace oil pan if necessary. 6. Remove the oil filter. 7. Clean and inspect the oil filter sealing area on the engine block, repair or replace if necessary. Installation Procedure 1. Lightly oil the replacement oil filter gasket with clean oil. Refer to Maintenance Items. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 2394 2. Install the new oil filter. Tighten the new oil filter to 3/4 to 1 full turn, after the oil filter gasket contacts the oil filter mounting surface. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the engine oil pan drain plug. Tighten the engine oil pan drain plug to 25 Nm (18 ft. lbs.). 4. Remove the oil drain pan. 5. Lower the vehicle. 6. Fill the engine with new engine oil. Refer to Capacities - Approximate Fluid. 7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the oil level indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, readjust the oil level by adding or draining the engine oil. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Throttle Body Heater Hose Replacement - Inlet Coolant Line/Hose: Service and Repair Throttle Body Heater Hose Replacement - Inlet Removal Procedure 1. Carefully disconnect the throttle body air inlet duct. 2. Drain the cooling system. Refer to Draining and Filling Cooling System. 3. Disconnect the throttle body inlet hose clamp and the hose (3) from the coolant pipe. 4. Disconnect the throttle body inlet hose (3) from the throttle body. 5. Remove the throttle body inlet hose (3). Installation Procedure 1. Install the throttle body inlet hose (3). 2. Connect the throttle body inlet hose and the clamp (3) to the throttle body. 3. Connect the throttle body inlet hose and the clamp (3) to the coolant pipe. 4. Install the throttle body air inlet duct. 5. Fill the cooling system. Refer to Draining and Filling Cooling System. 6. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Throttle Body Heater Hose Replacement - Inlet > Page 2400 Coolant Line/Hose: Service and Repair Throttle Body Heater Hose Replacement - Outlet Removal Procedure 1. Carefully disconnect the throttle body air inlet duct. 2. Drain the cooling system. Refer to Draining and Filling Cooling System. 3. Disconnect the throttle body outlet hose clamp and the hose (4) from the coolant pipe. 4. Disconnect the throttle body outlet hose clamp and the hose (4) from the throttle body. 5. Remove the throttle body outlet hose (4). Installation Procedure 1. Install the throttle body outlet hose (4). 2. Connect the throttle body outlet hose and the clamp (4) to the throttle body. 3. Connect the throttle body outlet hose and the clamp (4) to the coolant pipe. 4. Install the throttle body air inlet duct. 5. Fill the cooling system. Refer to Draining and Filling Cooling System. 6. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Specifications Heater Hose: Specifications Heater Inlet Pipe Nut 7 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Handling of Refrigerant Lines and Fittings Heater Hose: Service and Repair Handling of Refrigerant Lines and Fittings ^ Ensure that the metal lines do not exhibit the following conditions. This will prevent the loss of system capacity due to line restriction: Dents - kinks ^ Do not bend the flexible hose line to a radius of less that 4 times the diameter of the hose. ^ Do not allow the flexible hose line to come within a distance of 63.5 mm (2 1/2 in) of the exhaust manifold. ^ Inspect the flexible hose lines regularly. Replace the flexible hose line with new hose if one of the following conditions exist: Leaks - Brittleness - Deterioration ^ Before disconnecting any fitting in the refrigeration system, discharge all of the Refrigerant-134a. ^ Once you open a refrigerant line to the atmosphere, cap or tape the line immediately. This will prevent any of the following items from entering the line: Moisture - Dirt ^ Use the proper wrenches when you make connections on the O-ring fittings. Back-up the opposing fitting with a wrench in order to prevent distortion of the following areas: The connecting lines - The components ^ Tighten all of the tubing connections to the specified torque. ^ Too much or too little torque may result in the following conditions: Loose joints - Deformed joint parts - Refrigerant leakage - An inoperative A/C system ^ Ensure that the O-rings and the seats are in perfect condition. A burr or a piece of dirt may cause a refrigerant leak. ^ Install new O-rings that you have lubricated with the mineral base 525 viscosity refrigerant oil. Do not use Polyalkylene Glycol (PAG) synthetic oil. Do not wipe the threads with a cloth. ^ Keep PAG synthetic refrigerant oil off fitting threads. Long term contact of PAG synthetic oil on threads may cause future disassembly difficulties. Flush threads of fitting with mineral base 525 viscosity refrigerant oil. Do not use PAG synthetic oil. Do not wipe threads with a cloth. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Handling of Refrigerant Lines and Fittings > Page 2406 Heater Hose: Service and Repair Heater Hoses Replacement REMOVAL PROCEDURE Tools Required J 38185 Hose Clamp Pliers 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling. 2. Use J 38185 in order to position aside the heater hose inlet and/or outlet clamp. 3. Disconnect the heater inlet hose and/or the outlet hose from the inlet and/or outlet pipe. 4. Use J 38185 in order to position aside the heater core inlet and/or outlet hose clamp. 5. Disconnect the heater inlet hose and/or the outlet hose from the heater core. 6. Remove the heater inlet hose and/or the outlet hose. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Handling of Refrigerant Lines and Fittings > Page 2407 1. Install the heater inlet hose and/or outlet hose. 2. Connect the heater inlet hose and/or the outlet hose to the heater core. IMPORTANT: Position heater core hose clamps in the indicated location. 3. Use J 38185 in order to secure the heater core hose inlet and/or outlet clamp. 4. Connect the heater inlet hose and/or the outlet hose to the inlet and/or outlet pipe. 5. Use J 38185 in order to secure the heater hose inlet and/or outlet clamp. 6. Refill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Handling of Refrigerant Lines and Fittings > Page 2408 Heater Hose: Service and Repair Heater Pipe Replacement - Inlet TOOLS REQUIRED J 38185 Hose Clamp Pliers 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling. 2. Remove the air cleaner and duct assembly. 3. Disconnect the inlet hose (3) from the inlet pipe. 4. Use J 38185 in order to position aside the heater hose inlet clamp. 5. Remove the inlet pipe mounting nut. 6. Remove the inlet pipe. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Handling of Refrigerant Lines and Fittings > Page 2409 1. Install the inlet pipe. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the inlet pipe mounting nut. Tighten Tighten the heater inlet pipe nut to 7 N.m (62 lb in). 3. Connect the inlet hose (3) to the inlet pipe. 4. Use J 38185 in order to position the heater hose inlet clamp. 5. Install the air cleaner and duct assembly. 6. Refill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications Compressor Hose to Accumulator Nut 16 Nm Compressor Hose to Compressor Nut/Bolt 33 Nm Compressor Hose to Condenser Nut 16 Nm Suction Hose at Block Fitting Bolt 16 Nm Suction Hose Nut at Accumulator 47 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement Hose/Line HVAC: Service and Repair Compressor Hose Assembly Replacement REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the air cleaner and duct assembly. 3. Remove the cross vehicle brace. 4. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 5. Remove the compressor hose nut from the condenser and position the compressor hose aside. 6. Remove the compressor hose nut from the accumulator and position the compressor hose aside. 7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 8. Remove the lower air deflector. IMPORTANT: Remove and discard all the used O-rings and sealing washers. 9. Remove the compressor line at the compressor. 10. Remove the compressor hose assembly. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 2415 1. Install the compressor hose assembly. IMPORTANT: Lubricate the new O-rings with mineral base 525 viscosity refrigerant oil. 2. Install the new O-rings onto the compressor hose assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the compressor hose assembly at the rear of the compressor. Tighten Tighten the compressor hose bolt to 33 N.m (24 lb ft). 4. Install the compressor hose to the accumulator. 5. Install the compressor hose nut onto the accumulator. Tighten Tighten the compressor hose nut to 16 N.m (12 lb ft). 6. Install the compressor hose to the condenser. 7. Install the compressor hose nut. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 2416 Tighten Tighten the compressor hose nut to 16 N.m (12 lb ft). 8. Install the lower air deflector. 9. Lower the vehicle. 10. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. See: Fluids/Refrigerant/Service and Repair 11. Inspect the system for leaks. Refer to Leak Testing. 12. Install the cross vehicle brace. 13. Install the air cleaner and duct assembly. 14. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 2417 Hose/Line HVAC: Service and Repair Condenser Tube Replacement REMOVAL PROCEDURE 1. Remove the air cleaner and duct assembly. 2. Remove the cross vehicle brace. 3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 4. Remove the vacuum brake booster. 5. Remove the liquid line from the bracket. 6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 7. Remove the lower air deflector. 8. Disconnect the electrical connector (2) from the A/C refrigerant pressure sensor (1). 9. Remove the liquid line nut at the condenser. 10. Lower the vehicle. 11. Remove the liquid line nut at the orifice. 12. Disconnect the transmission shift cable retainer from the strut tower and position aside the transmission shift cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 2418 IMPORTANT: Use care when removing the tube. 13. Remove the liquid line. 14. Remove and discard the O-rings. INSTALLATION PROCEDURE IMPORTANT: The new O-ring seals must be lubricated with mineral base 525 viscosity refrigerant oil. 1. Install new O-ring seals onto the liquid line. 2. Install the liquid line into place. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the liquid line nut at the orifice. Tighten Tighten the liquid line nut to 27 N.m (20 lb ft). 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 5. Install the liquid line nut at the condenser. Tighten Tighten the liquid line nut to 27 N.m (20 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 2419 6. Connect the electrical connector (2) to the A/C refrigerant pressure sensor (1). 7. Install the lower air deflector. 8. Lower the vehicle. 9. Install the liquid line into the bracket. 10. Install the vacuum brake booster. 11. Evacuate and charge the system. Refer to Refrigerant Recovery and Recharging. See: Fluids/Refrigerant/Service and Repair 12. Inspect the system for leaks. 13. Install the cross vehicle brace. 14. Install the air cleaner and duct assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 2420 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement REMOVAL PROCEDURE 1. Remove the air cleaner and duct assembly. 2. Remove the cross vehicle brace. 3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 4. Remove the liquid/suction line bracket. 5. Remove the vacuum brake booster. 6. Remove the liquid line nut at the orifice. 7. Remove the liquid line at the block fitting. IMPORTANT: Use care when removing the liquid line. 8. Remove the liquid line. 9. Remove and discard the O-rings. INSTALLATION PROCEDURE IMPORTANT: The new O-ring seals must be lubricated with mineral base 525 viscosity refrigerant oil. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 2421 1. Install the new O-ring seals onto the liquid line. Refer to O-ring Replacement. 2. Install the liquid line into place. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the liquid line at the block fitting. Tighten Tighten the liquid line block fitting bolt to 16 N.m (12 lb ft). 4. Install the liquid line nut at the orifice. Tighten Tighten the liquid line nut to 27 N.m (20 lb ft). 5. Install the liquid line/suction line bracket. 6. Install the vacuum brake booster. 7. Evacuate and charge the system. Refer to Refrigerant Recovery and Recharging. See: Fluids/Refrigerant/Service and Repair 8. Inspect the system for leaks. Refer to Leak Testing. 9. Install the cross vehicle brace. 10. Install the air cleaner and duct assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 2422 Hose/Line HVAC: Service and Repair Suction Hose Replacement REMOVAL PROCEDURE 1. Remove the air cleaner and duct assembly. 2. Remove the cross vehicle brace. 3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 4. Remove the brake modulator bracket. 5. Remove the liquid/suction line bracket. 6. Remove the suction line nut at the accumulator and position aside the suction line. 7. Remove the suction line block fitting bolt. IMPORTANT: Use care when removing the suction line. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 2423 8. Remove the suction line. 9. Remove and discard the suction line O-rings seals. INSTALLATION PROCEDURE IMPORTANT: The new O-ring seals must be lubricated with mineral base 525 viscosity refrigerant oil. 1. Install the new O-ring seals onto the suction line. 2. Install the suction line into place. 3. Install the suction line into the block fitting. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the suction line block fitting bolt. Tighten Tighten the suction line block fitting bolt to 16 N.m (12 lb ft). 5. Install the suction line to the accumulator. Tighten Tighten the suction line nut to 47 N.m (35 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 2424 6. Install the liquid/suction line bracket. 7. Install the brake modulator bracket. 8. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. See: Fluids/Refrigerant/Service and Repair 9. Inspect the A/C system for leaks. Refer to Leak Testing. 10. Install the cross vehicle brace. 11. Install the air cleaner and duct assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Fastener Tightening Specifications Power Steering Line/Hose: Specifications Power Steering Cooler Pipe Bolt 84 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Fastener Tightening Specifications > Page 2429 Power Steering Line/Hose: Specifications Power Steering Return Hose Clamp Fitting to Power Steering Pump 20 ft.lb Power Steering Pressure Line Fitting to Power Steering Gear 20 ft.lb Power Steering Pressure Line Fitting to Power Steering Pump 20 ft.lb Power Steering Return Line Fitting to Power Steering Gear 20 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hoses Replacement Power Steering Line/Hose: Service and Repair Power Steering Hoses Replacement Removal Procedure 1. Place a drain pan under the vehicle. 2. Remove the clamps from the power steering return line to the power steering pump. 3. Remove the rubber section of hose that connects the power steering return line to the power steering pump. 4. Remove the rubber section of the power steering return line from the vehicle. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the clamps from the power steering return line and the power steering cooler pipe. 7. Remove the rubber section of hose that connects the power steering return line to the power steering cooler pipe. 8. Remove the rubber section of the power steering return line from the vehicle. Installation Procedure 1. Position the rubber section of the power steering return line to the vehicle. 2. Install the rubber section of hose that connects the power steering return line to the power steering cooler pipe. 3. Install the clamps to the power steering return line and the power steering cooler pipe. 4. Lower the vehicle. 5. Position the rubber section of the power steering return line to the vehicle. 6. Install the rubber section of hose that connects the power steering return line to the power steering pump. 7. Install the clamps to the rubber section of hose that connects the power steering return line to the power steering pump. 8. Remove the drain pan from under the vehicle. 9. Fill the power steering system. Refer to Refilling the Power Steering System. 10. Bleed the power steering system. Refer to Bleeding the Power Steering System. 11. Inspect the power steering system for leaks. Refer to Steering and Suspension Leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hoses Replacement > Page 2432 Power Steering Line/Hose: Service and Repair P/S Cooler Pipe/Hose Replacement Removal Procedure 1. Remove the engine mount struts from the engine. Refer to Engine Mount Strut Replacement (Left) and Engine Mount Strut Replacement (Right) in Engine. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 4. Place a drain pan under the vehicle. Notice: The front wheels of the vehicle must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. Failure to follow these procedures will cause improper alignment of some components during installation and result in damage to the SIR coil assembly. 5. Remove the intermediate steering shaft from the power steering gear stub shaft. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column - Tilt. 6. Use a utility stand in order to support the frame. 7. Remove the frame bolts from the rear of the frame. Refer to Frame Removal in Frame and Underbody. Notice: Do not lower the rear of the frame too far as damage to the engine components nearest to the cowl may result. 8. Use the utility stand in order to lower the rear of the frame to gain access. 9. Remove the power steering return hose from the power steering pump to the power steering cooler pipe. 10. Remove the power steering return line from the power steering gear. 11. Remove the power steering return line from the clamp on the power steering gear. 12. Remove the power steering cooler pipe retaining clips. 13. Remove the power steering cooler pipe from the vehicle. Installation Procedure 1. Install the power steering cooler pipe to the vehicle. 2. Install the power steering cooler pipe retaining clips. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hoses Replacement > Page 2433 3. Install the power steering return line to the power steering gear. Refer to Power Steering Return Hose Replacement. 4. Install the power steering return line to the clamp on the power steering gear. 5. Install the power steering return hose from the power steering pump to the power steering cooler pipe. 6. Use the utility stand in order to raise the frame. 7. Install NEW frame bolts to the rear of the frame. Refer to Frame Removal in Frame and Underbody. 8. Install the intermediate steering shaft to the power steering gear stub shaft. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column-Tilt. 9. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 10. Remove the drain pan from under the vehicle. 11. Lower the vehicle. 12. Install the engine mount struts to the engine. Refer to Engine Mount Strut Replacement (Left) and Engine Mount Strut Replacement (Right) in Engine. 13. Fill the power steering fluid reservoir. Refer to Refilling the Power Steering System. 14. Bleed the power steering system. Refer to Bleeding the Power Steering System. 15. Inspect the power steering system for leaks. Refer to Steering and Suspension Leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hoses Replacement > Page 2434 Power Steering Line/Hose: Service and Repair P/S Pressure Hose Replacement Removal Procedure 1. Place a drain pan under the vehicle. 2. Remove the power steering pressure line from the power steering pump. 3. Remove the power steering pressure line from the power steering lines retaining bracket on the engine. 4. Remove the power steering line from the power steering gear performing the following steps: 4.1. The power steering pressure line is the lower line at the power steering gear. 4.2. Using a 18 mm (crow's foot line wrench with a 2 foot long, 3/8 inch drive extension). 4.3. Access the line from the engine compartment, between the rocker arm cover and the front of the dash mat. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hoses Replacement > Page 2435 6. Remove the power steering pressure line (1) from the clamps on the power steering gear. 7. Remove the power steering pressure line (1) from the vehicle. Installation Procedure 1. Install the power steering pressure line (1) to the vehicle. 2. Install the power steering pressure line (1) to the clamps on the power steering gear. 3. Lower the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the power steering pressure line to the power steering gear. Use a 18 mm crow's foot line wrench with a 2 foot long, 3/8 inch drive extension. Tighten the power steering pressure line fitting to the power steering gear to 27 Nm (20 ft. lbs.). 5. Install the power steering pressure line to the power steering lines retaining bracket on the engine. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hoses Replacement > Page 2436 6. Install the power steering pressure line to the power steering pump. Tighten the power steering pressure line fitting to the power steering pump to 27 Nm (20 ft. lbs.). 7. Fill the power steering system with power steering fluid. Refer to Refilling the Power Steering System. 8. Bleed the power steering system. Refer to Bleeding the Power Steering System. 9. Inspect the power steering system for leaks. Refer to Steering and Suspension Leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hoses Replacement > Page 2437 Power Steering Line/Hose: Service and Repair P/S Return Line Replacement Removal Procedure 1. Place a drain pan under the vehicle in order to catch any draining power steering fluid. 2. Remove the power steering return hose from the power steering pump. 3. Remove the power steering return hose from the power steering lines retaining bracket on the engine. 4. Remove the power steering return hose from the power steering cooler pipe. 5. Remove the power steering return hose from the vehicle. Installation Procedure 1. Install the power steering return hose. 2. Install the power steering return hose to the power steering cooler pipe. 3. Install the power steering return hose to the power steering lines retaining bracket on the engine. 4. Install the power steering return hose to the power steering pump. 5. Fill the power steering system. Refer to Refilling the Power Steering System 6. Bleed the power steering system. Refer to Bleeding the Power Steering System 7. Inspect the power steering system for leaks. Refer to Steering and Suspension Leaks 8. Remove the drain pan from under the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet Radiator Hose: Service and Repair Radiator Hose Replacement - Inlet Removal Procedure - Tools Required J 38185 Hose Clamp Pliers 1. Partially drain the cooling system. Refer to Draining and Filling Cooling System. 2. Remove the left diagonal brace. Refer to Brace Replacement - Front Fender Upper Diagonal (impala) or Brace Replacement - Front Fender Upper Diagonal (Monte Carlo) in Body and Frame. 3. Use the J 38185 in order to reposition the hose clamp at the thermostat housing. Disconnect the inlet hose (1) from the thermostat housing 4. Use the J 38185 in order to reposition the hose clamp at the radiator. 5. Disconnect the inlet hose from the radiator. Remove the inlet hose. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 2442 1. Align the marks on the hose. Install the inlet hose to the radiator. 2. Use the J 38185 in order to reposition and install the hose clamp at the radiator. 3. Connect the inlet hose (1) to the thermostat housing. 4. Use the J 38185 in order to reposition and install the inlet hose at the thermostat housing. 5. Install the left diagonal brace. Refer to Brace Replacement - Front Fender Upper Diagonal (Impala) or Brace Replacement - Front Fender Upper Diagonal (Monte Carlo) in Body and Frame. 6. Fill the cooling system. Refer to Draining and Filling Cooling System. 7. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 2443 Radiator Hose: Service and Repair Radiator Hose Replacement - Outlet Removal Procedure - Tools Required J 38185 Hose Clamp Pliers 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Use the J 38185 in order to reposition the hose clamp at water pump housing. 3. Disconnect the outlet hose (2) from the water pump housing. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Remove the radiator lower air deflector. Refer to Radiator Air Baffle Assemblies and Deflectors (Upper) or Radiator Air Baffle Assemblies and Deflectors (Side) or Radiator Air Baffle Assemblies and Deflectors (Lower). 6. Use the J 38185 in order to reposition the hose clamp at radiator. 7. Disconnect the outlet hose from the radiator. Remove the outlet hose. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 2444 1. Align the marks on the hose. Install the outlet hose to the radiator. 2. Use the J 38185 in order to reposition and install the hose clamp at the radiator. 3. Install the radiator lower air deflector. Refer to Radiator Air Baffle Assemblies and Deflectors (Upper) or Radiator Air Baffle Assemblies and Deflectors (Side) or Radiator Air Baffle Assemblies and Deflectors (Lower). 4. Lower the vehicle. 5. Connect the outlet hose to the water pump housing (2). 6. Use the J 38185 in order to reposition and install the hose clamp at the water pump housing. 7. Fill the cooling system. Refer to Draining and Filling Cooling System. 8. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Brake Fluid - Level & Filling Recommendations Brake Fluid: Technical Service Bulletins Brake Fluid - Level & Filling Recommendations File In Section: 05 - Brakes Bulletin No.: 00-05-22-004 Date: May, 2000 INFORMATION Subject: Brake Fluid Level and Filling Recommendations Models: 2001 and Prior Passenger Cars and Trucks Many dealers and after-market repair shops advertise multi-point fluid "top-ups" in conjunction with oil changes or regular maintenance packages. These offers often include adding brake fluid to the master cylinder reservoir. There are only two reasons why the brake fluid level in the brake reservoir might go down. The first is that the brake fluid level goes down an acceptable level during normal brake lining wear. When the linings are replaced, the fluid will return to it's original level. The second possible reason for a low fluid level is that fluid is leaking out of the brake system. If fluid is leaking, the brake system requires repair and adding additional fluid will not correct the leak. If the system was properly filled during delivery of the vehicle, no additional fluid should be required under most circumstances between brake pad and/or shoe replacements. This information can be reinforced with the customer by referring them to the Brake Fluid section of their vehicle's Owner's Manual. Guidelines GM vehicles have incorporated a variety of brake fluid reservoir styles. The following guidelines are restricted to the plastic bodied fluid reservoirs and do not affect the original service recommendations for the older style metal bodied units. You may encounter both black plastic and translucent style reservoirs. You may have reservoirs with: ^ A MAX fill mark only ^ A MIN fill mark only ^ Both MAX and MIN marks The translucent style reservoirs do not have to have the covers removed in order to view the fluid level. It is a good practice not to remove the reservoir cover unless necessary to reduce the possibility of contaminating the system. Use the following guidelines to assist in determining the proper fluid level. Important: When adding brake fluid, use Delco Supreme II(R) Brake Fluid, GM P/N 12377967 or equivalent brand bearing the DOT-3 rating only. Important: At no time should the fluid level be allowed to remain in an overfilled condition. Overfilling the brake reservoir may put unnecessary stress on the seals and cover of the reservoir. Use the following guidelines to properly maintain the fluid level. If the reservoir is overfilled, siphon out the additional fluid to comply with the guidelines below. Important: If under any circumstance the brake fluid level is extremely low in the reservoir or the BRAKE warning indicator is illuminated, the brake system should be checked for leaks and the system repaired in addition to bringing the fluid level up to the recommended guidelines outlined below. A leaking brake system will have reduced braking performance and will eventually not work at all. Important: Some vehicles have reservoirs that are very sensitive to brake fluid levels and may cause the BRAKE indicator to flicker on turns as the fluid approaches the minimum required level. If you encounter a vehicle with this concern, increase the fluid level staying within the guidelines outlined below. ^ If the reservoir has a MAX level indicator, the reservoir should be returned to the MAX marking only at the time new brake pads and/or shoes are installed. If the reservoir fluid level is at the half-way point or above do not attempt to add additional brake fluid during routine fluid checks. ^ If the reservoir has both MAX and MIN indicators, the fluid level should be maintained above the MIN indicator during routine fluid checks and returned to the MAX indication only after new brake pads and/or shoes are installed. ^ For reservoirs with only a MIN indication, the fluid level should be maintained above the MIN indicator during routine fluid checks. Return the Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Brake Fluid - Level & Filling Recommendations > Page 2450 reservoir fluid level to full only after installing new brake pads and/or shoes. A full reservoir is indicated on translucent, snap cover reservoirs by a fluid level even with the top level of the view window imprinted into the side of the reservoir. On screw top models in black or translucent plastic, the full level is just below the bottom of the filler neck. Parts Information Part Number Description 12377967 Brake Fluid Parts are currently available from GMSPO. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 2451 Brake Fluid: Specifications Brake Fluid Type Delco Supreme II (R) Fluid, GM P/N 12377967 Or DOT-3 Equivalent Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2456 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2457 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2458 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2459 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity 11.3 qt (US) Note: Recheck fluid level after filling system. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 2462 Coolant: Fluid Type Specifications Type Goodwrench(R) or Havoline(R) Silicate-Free DEX-COOL(R) Coolant/Water Mixture 50/50 % Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 2463 Coolant: Service and Repair Ethylene glycol/water fill ratios have been established to ensure a minimum of 50 percent ethylene glycol. Ensure that all the engine block drains and air bleeds are utilized. The cooling system capacity for the 3.41L is 10.4 liters (10.9 quarts). The cooling system capacity for the 3.81L is 9.6 liters (10.1 quarts). The quantities listed in the filling procedure include the additional quantity to displace the air remaining in the cooling system after a static refill. Unless the cooling system is completely drained, residual coolant reduces the amount of coolant required to fill the system. Always check the freeze point protection after filling a cooling system. Using the correct fill ratio and the following procedures will ensure a minimum concentration of 50 percent ethylene glycol. Every five years or 240,000 km, (150,000 miles), whichever occurs first, the cooling system should be drained and filled using the following procedure. Caution: As long as there is pressure in the cooling system, the temperature can be considerably higher than the boiling temperature of the solution in the radiator without causing the solution to boil. Removal of the pressure cap while the engine is hot and pressure is high will cause the solution to boil instantaneously -possibly with explosive force - spewing the solution over the engine, fenders and the person removing the cap. Notice: When adding coolant, it is important that you use GM Goodwrench DEX-COOL(R) or HAVOLINE(R) DEX-COOL(R) coolant. If Coolant other than DEX-COOL(R) or HAVOLINE(R) DEX-COOL(R) is added to the system the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months. Draining Procedure Important: This procedure significantly increases the amount of used coolant and diluted hazardous waste. 1. Park the vehicle on a level surface. 2. Remove and clean coolant recovery reservoir. 3. Remove the radiator cap when the engine is cool: 3.1. Slowly rotating the cap counterclockwise to the detent. Do not press down while rotating pressure cap. 3.2. Wait until any residual pressure (indicated by a hissing sound) is relieved. 3.3. After all hissing stops, continue to rotate the cap counterclockwise. Important: Store the used coolant in a used coolant holding tank. Submit the used coolant for recycling. 4. Place a drain pan under vehicle to collect all the drained coolant. Important: For procedures requiring the cooling system to be partially drained, opening the radiator drain valve should provide sufficient draining and no further actions should be necessary. 5. Open the radiator drain valve located at the bottom of the radiator tank. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 2464 6. 3.4L - Open the air bleed vent (1) on the thermostat housing. The air bleed vent should be opened two to three turns. 7. 3.4L - Open the air bleed vent (1) on the thermostat bypass pipe. The air bleed vent should be opened two to three turns. 8. 3.8L - Open the air bleed vent (1) on the thermostat housing. The air bleed vent should be opened two to three turns. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 2465 9. 3.4L - Remove the engine block coolant drain plug from the engine left side. 10. 3.4L - Remove the engine block coolant drain plug from the engine right side. 11. 3.8L - Remove both block drains (knock sensors). Important: Dispose of used coolant in a proper fashion. Never pour used coolant down the drain. Ethylene glycol antifreeze is a very toxic chemical; disposing of it into the sewer system or ground water is both illegal and ecologically unsound! 12. Allow the coolant to drain completely. Filling Procedure Notice: DO NOT use cooling system seal tabs (or similar compounds) unless otherwise instructed. The use of cooling system seal tabs (or similar compounds) may restrict coolant flow through the passages of the cooling system or the engine components. Restricted coolant flow may cause engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 2466 overheating and/or damage to the cooling system or the engine components/assembly. 1. Close the radiator drain valve. 2. 3.8L - Install both block drains (knock sensors). 3. 3.4L - Install the engine block coolant drain plug to the engine right side. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 2467 4. 3.4L - Install the engine block coolant drain plug to the engine left side. 5. Remove the coolant recovery reservoir and empty. Flush the reservoir with clean water. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement. Important: When filling the cooling system, add GM approved Ethylene Glycol Coolant DEX-COOL GM P/N 12346290. - If the cooling system is being refilled ONLY (no flush), a 50 percent ethylene glycol and 50 percent clean drinkable water mixture should be used to fill the system. Fill the system until the level of the 50/50 mixture has reached the base of the radiator neck. Wait two minutes. Check the level of the coolant mixture. Add a 50/50 ethylene glycol/water mixture as necessary to restore the coolant mixture level to the base of the radiator neck. 6. Slowly fill the cooling system through the radiator neck using the following procedure: 6.1. If the coolant system has been flushed first add 100 percent ethylene glycol: - 3.4L - 5.2 L (5.45 qt.) - 3.8L - 4.8 L (5.05 qt.) 6.2. Slowly add clean drinkable water to the system until the level of the coolant mixture has reached the base of the radiator neck. 6.3. Wait for two minutes. Check the level of the coolant mixture. Add clean drinkable water if necessary to restore the coolant mixture level to the base of the radiator neck. 7. Install the radiator cap making certain the arrows line up with the overflow tube. 8. 3.8L - Close the air bleed valve (1) on the thermostat housing. Important: DO NOT over-torque the air bleed valve. The air bleed valve is made out of brass. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 2468 9. 3.4L - Close the air bleed valve (1) on the thermostat bypass pipe. 10. 3.4L - Close the air bleed valve (1) on the thermostat housing. 11. Fill the coolant recovery reservoir to the COLD mark with of a 50/50 mixture of ethylene glycol and clean drinkable water. Notice: The Low Coolant warning/indicator lamp may come on after this procedure. If after operating the vehicle so that the engine heats up and cools down three times, the Low Coolant warning/indicator lamp does not go out, or fails to come on at the ignition check, and the coolant is above the full cold mark in the reservoir, refer to Low Coolant Warning/indicator Lamp in Instrument Panel, Gauges and Warning Indicators. If at any time the Temperature warning/indicator lamp comes on, immediate action is required. Turn OFF the engine and allow the vehicle to cool. Do not remove the coolant recovery reservoir cap at this time. 12. Inspect the freeze protection of the engine coolant after the engine heats up and cools down three times using a refractometer or a thermohydrometer to ensure proper freeze -37° C (-34° F) protection. Obtain the coolant mixture for the inspection from the base of the radiator neck, NOT from the coolant recovery reservoir. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 2473 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 2474 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 2475 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 2476 Fluid - A/T: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Pan Removal ........................................................................................................ ............................................................................................. 7.0L (7.4 Qt) Overhaul ........................... .............................................................................................................................................................. ................. 9.5L (10.0 Qt) Dry .............................................................................................................. .................................................................................................. 12.7L (13.4 Qt) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 2479 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 2484 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 2485 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 4.2L (4.5 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2488 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Grade ............................................................... ..................................................................................................... 5W-30 (preferred), 10W-30 if above 0° F Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 2489 Engine Oil: Service Precautions Look for and use ONLY engine oil that meets GM Specification. Oil that does not have the correct specification designation can cause engine damage not covered by warranty. Do NOT use engine oil additives. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Noise Diagnostics TSB References Power Steering Fluid: Technical Service Bulletins Steering - Noise Diagnostics TSB References INFORMATION Bulletin No.: 06-02-32-009B Date: November 19, 2008 Subject: Overview of Steering System Noises Models: 2001-2004 Buick Regal 2001-2005 Buick Century 2005-2007 Buick Allure (Canada Only), LaCrosse 2000-2006 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo 1998-2002 Oldsmobile Intrigue 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to remove reference to Corporate Bulletin Number 01-02-32-001 from the table below. Please discard Corporate Bulletin Number 06-02-32-009A (Section 02 - Steering). The purpose of this bulletin is to provide a quick reference for dealers to aid in locating the correct service bulletin for several different steering system noise concerns. Many customer concerns with the steering system involve specific symptoms (noises heard). Once the customer concern has been verified, the table above may help identify the correct bulletin to reference. If other symptoms are present, or if diagnosis indicates another cause not found in any of the three service bulletins, refer to SI to diagnose the repair customer concern. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Complete system 1.5 pt (US) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 2496 Power Steering Fluid: Fluid Type Specifications x x Power Steering Fluid GM Power Steering Fluid (GM P/N 1050017 - 1 quart or Equivalent) Cold Climate Power Steering Fluid 12345866 or Equivalent Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 2501 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 2502 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 2503 Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recharge Equipment File In Section: 01 - HVAC Bulletin No.: 99-01-38-006A Date: May, 2000 WARRANTY ADMINISTRATION Subject: J-43600 ACR 2000 Essential Refrigerant Recovery/Recharge Equipment Models: 1993-2000 Passenger Cars and Light Duty Trucks with R-134a Refrigerant This bulletin is being revised to change the effective date and to update the text. Please discard Corporate Bulletin Number 99-01-38-006 (Section 01 - HVAC). Effective June 1, 2000, the use of J-43600 ACR 2000 will be required on all repairs that require A/C system recovery and are reimbursable by GM. Additionally, GM highly recommends that J-43600 ACR 2000 be used on all GM cars and trucks for customer paid A/C repairs. Important: Also effective June 1, 2000, the "Add" time for all air conditioning recovery is revised to 0.5 hours for front systems and 0.7 hours for front/rear dual systems (RPO C69 or C34). After June 1, 2000, all air conditioning claims submitted with the 0.9 hours "Add" time will be rejected for "labor hours excessive". After the completion of repairs (charging), the ACR 2000 will prompt the user to perform a snapshot of the air conditioning system operating data. The snapshot includes: ^ Maximum high side pressure. ^ Minimum low side pressure. ^ Duct outlet temperatures (2). ^ Refrigerant purity information. This information is captured on a paper printout and in a warranty code. For all GM paid repairs, the paper printout should be attached to the shop copy of the repair order. The warranty code must be submitted in the warranty claim information in the comments field. The code enables the reporting of valuable information about the repair to GM for product quality improvement. Claims submitted without this information may be subject to review and subsequent debit. The required use of J-43600 ACR 2000 raises the question of the acceptable uses for any existing recovery/recycle equipment that GM dealers are currently using. GM recognizes that many of the previously essential ACR4's are reaching the end of their useful life. There are several alternatives for existing equipment that may be considered: ^ Use the existing equipment as customer paid recovery only equipment. Example: Collision repair area. ^ Use the existing equipment as a scavenger unit for contaminated A/C systems. ^ Sell the existing units to repair facilities outside the GM dealer network. ^ Discontinue the use of the existing units if the repair/maintenance costs exceed the value of the equipment. ^ Donate the existing equipment to local technical schools. ^ Dedicate the ACR4 to A/C system flushing, using the J-42939 Flush Adapter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 2504 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity ............................................................................................................................ ......................................................................... 1.0 kg Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 2507 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ..................................................................... R-134a Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 2508 Refrigerant: Description and Operation CAUTION: Refer to Breathing R-134a Caution in Service Precautions. Refrigerant performs the following functions in the air conditioning system: ^ Absorbs heat ^ Carries heat ^ Releases heat These vehicles use Refrigerant-134a (R-134a). Refrigerant-134a is a nontoxic, nonflammable, clear, colorless liquefied gas. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 2509 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED ^ J 39500-B A/C Refrigerant Recovery, Recycling and Recharging (ACR4) System ^ J 41810 Pure Guard 2 ^ J 41810-100A Active Flow Control Valve CAUTION: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: ^ R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. ^ To avoid system damage use only R-134a dedicated tools when servicing the A/C system. ^ Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. ^ R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 39500-B removes the Refrigerant - 134a from the vehicle's A/C system. The recovery procedure uses one filtering cycle. The evacuation procedure uses an automatic multiple pass filtering cycle. These filtering cycles ensure a constant supply of clean, dry refrigerant for the A/C system charging. The Initial Set-Up Instruction Manual, provided with the J 39500-B For ACR4 technical assistance in the U.S., call 1-800-345-2233. Refrigerant System Capacity For the amount of Refrigerant - 134a needed for A/C system (recharging). Refer to System Capacities. Refrigerant System Oil Charge Replenishing If refrigerant oil was removed from the A/C system during the recovery process, add the same amount of refrigerant oil to the system in the recharging process. The refrigerant oil must be replenished if the oil loss is due to component replacement or abrupt loss. Refer to Refrigerant Oil Distribution Specifications. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications System Capacity Polyalkaline Glycol (PAG) Refrigerant Oil System Capacity................................................................................................................................... ............................................... 8.45 fl. oz. (250 ml) Refrigerant Oil Distribution Specifications If the refrigerant oil was removed from the A/C system during the recovery process or during the component replacement, the refrigerant oil must be replenished. Add the refrigerant oil as indicated. Accumulator ......................................................................................................................................... .......................................................................... 30 ml Compressor .................................................... .............................................................................................................................................................. .. 60 ml Condenser .............................................................................................................................. ........................................................................................ 30 ml Evaporator ........................................ .............................................................................................................................................................. ................ 90 ml Abrupt Loss ............................................................................................................... ..................................................................................................... 90 ml NOTE: Replacement compressors do not have any oil in the compressor. Add the correct amount of oil to the replacement compressor before replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 2516 Refrigerant Oil: Fluid Type Specifications Internal Lubricant ............................................................................................................................. Poly-Alkaline Glycol (PAG) Synthetic Refrigerant Oil Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2517 Refrigerant Oil: Service and Repair Use approved compressor oil from a closed, sealed container. When adding refrigerant oil, the transfer device and container should be clean and dry to minimize the possibility of contamination. Refrigerant oil is moisture-free and will readily absorb moisture from the air. Do not open the oil container until the service procedure requires oil. Cap the oil immediately after use. Always store compressor oil in a closed sealed container. Compressor oil left in open or improperly sealed containers will absorb moisture. Do not reuse oil that has been removed from the refrigeration system. Dispose of used oil properly, according to local regulations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure Brake Bleeding: Service and Repair Automated Bleed Procedure Important: In most circumstances a base brake bleed is all that is required for most component replacements (such as wheel cylinders, calipers, brake tubes, and master cylinder), except for BPMV replacement. The following automated ABS bleed procedure is required when one of the following actions occur: ^ Manual bleeding at the wheels does not achieve the desired pedal height or feel. ^ BPMV (Brake Pressure Modulator Valve) replacement ^ Extreme loss of brake fluid has occurred. ^ Air ingestion is suspected. If none of the above conditions apply, use standard bleed procedures. Refer to Hydraulic Brake System Bleeding. The auto bleed procedure is used on DBC 7 equipped vehicles. This procedure uses a scan tool to cycle the system solenoid valves and run the pump in order to purge the air from the secondary circuits. These secondary circuits are normally closed off, and are only opened during system initialization at vehicle start up, and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped inside the BPMV to flow out toward the wheel cylinders or calipers where the air can be purged out of the system. Automated Bleed Procedure ^ Tools Required A scan tool - A 35 psi pressure bleeder with the proper master cylinder adapter - Delco Supreme 11 or equivalent Dot 3 brake fluid from a clean, sealed container - A hoist - An unbreakable plastic bleeder bottle equipped with a hose (in order to recover fluid at the wheels) - An assistant, if needed - Suitable safety attire, including safety glasses Preliminary Inspection 1. Inspect the battery for full charge, repair the battery and charging system as necessary. Refer to Battery Charging. 2. Connect a scan tool to the Data Link Connector (DLC) and select current and history DTCs. Repair any DTCs prior to performing the ABS bleed procedure. 3. Inspect for visual damage and leaks. Repair as needed. Preliminary Setup 1. Raise and support the vehicle on a suitable support. Refer to Vehicle Lifting. 2. Turn the ignition switch to the OFF position. 3. Remove all four tires, if necessary. 4. Connect the pressure bleeding tool according to the manufacturer's instructions. 5. Turn the ignition switch to RUN position, with the engine off. 6. Connect the scan tool and establish communications with the ABS system. 7. Pressurize the bleeding tool to 30 to 35 psi. Performing the Automated Bleed Procedure Notice: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. 1. With the pressure bleeding tool at 30 to 35 psi, and all bleeder screws in closed position, select Automated Bleed Procedure on the scan tool and follow the instructions. 2. The first part of the automated bleed procedure will cycle the pump and front release valves for 1 minute. After the cycling has stopped the scan tool will enter a "cool down" mode and display a 3 minute timer. The auto bleed will not continue until this timer expired, and cannot be overridden. 3. During the next step, the scan tool will request the technician to open one of the bleeder screws. The scan tool will then cycle the respective release valve and pump motor for 1 minute. 4. The scan tool will repeat step 3 for the remaining bleeder screws. 5. With the bleeder tool still attached to the vehicle and maintaining 35 psi, the scan tool will instruct the technician to independently open each bleeder screw for approximately 20 seconds. This should allow any remaining air to be purged from the brake lines. 6. When the automated bleed procedure is completed, the scan tool will display the appropriate message. 7. Remove pressure from the pressure bleeding tool, and then disconnect the tool from the vehicle. 8. Depress the brake pedal in order to gauge the pedal height and feel. Repeat step 1 through step 8 until the pedal height and feel is acceptable. 9. Remove the scan tool from the DLC connector. 10. Install the tire and wheels assemblies, if removed. 11. Lower the vehicle. 12. Inspect the brake fluid level in master cylinder. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 2522 13. Road test the vehicle in order to ensure that the brake pedal remains high and firm. If vehicle is equipped with TCS, the scan tool will cycle both the ABS and TCS solenoids valves. This bleed procedure is the same as the procedure above. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 2523 Brake Bleeding: Service and Repair Manual and Pressure Bleeding Procedures Caution: Do not move the vehicle until a firm brake pedal is obtained. Air in the brake system can cause loss of brakes with possible personal injury. Caution: Use only SUPREME II or equivalent DOT 3 brake fluid from a clean, sealed container. Do not use fluid from an open container that may be contaminated with water. Improper or contaminated fluid will result in damage to components or loss of braking, with possible personal injury. Caution: Do not overfill the brake fluid reservoir. Overfilling the brake fluid reservoir may cause the brake fluid to overflow onto the engine exhaust components during brake system service. The brake fluid is flammable and may cause a fire and personal injury if the brake fluid contacts the engine exhaust system components. Notice: If any brake component is repaired or replaced such that air is allowed to enter the brake system, the entire bleeding procedure must be followed. Notice: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring, cables, or electric connectors. Brake fluid will damage the paint and the electrical connections. If any fluid is spilled on the vehicle, flush the area to lessen the damage. Notice: Prior to bleeding the brakes, the front and rear displacement cylinder pistons must be returned to the topmost position, The preferred method uses a Scan Tool to perform the rehorning procedure. If a Scan Tool is not available, the second procedure may be used, but it is extremely important that the procedure be followed exactly as outlined. A bleeding operation is necessary in order to remove air when air is introduced into the hydraulic brake system. Bleed the hydraulic system at all four brakes if air has been introduced through a low fluid level or by disconnecting brake pipes at the master cylinder. If a brake hose or brake pipe is disconnected at one wheel, bleed only that one wheel caliper. If brake pipes or hoses are disconnected at any fitting located between the master cylinder and the brakes, then only bleed the brake system served by the disconnected pipe or hose. With Scan Tool (Preferred Method) Refer to Automated Bleed Procedure. Without Scan Tool Notice: This method can only be used if the amber ABS warning indicator is not illuminated and no DTCs are present. Important: Do not place your foot on the brake pedal through this entire procedure unless specifically directed to do so. 1. Remove foot from the brake pedal. 2. Start the engine. Allow the engine to run for at least ten seconds while observing the amber ABS warning indicator. 3. If the amber ABS warning indicator turns on and stays on after ten seconds, stop the bleeding procedure. Use a Scan Tool in order to diagnose the ABS malfunction. 4. If the amber ABS warning indicator turns on for approximately three seconds, then turns off and stays off, turn the ignition off. 5. Repeat the previous four steps one more time. 6. Bleed the entire brake system. Pressure Bleeding ^ Tools Required J 29532 Diaphragm Type Brake Bleeder Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 2524 - J 35589 Compact Brake Bleeder Adapter Notice: Pressure bleeding equipment must be of the diaphragm type. It must have a rubber diaphragm between the air supply and the brake fluid to prevent air, moisture, and other contaminants from entering the hydraulic system. 1. Inspect and fill the master cylinder reservoir to the proper level as necessary. 2. Assemble the components as shown. 3. Install the J 35589 to the master cylinder reservoir. 4. Connect the J 29532 to the J 35589. 5. Adjust the J 29532 to 35 - 70 kPa (5 - 10 psi). 6. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing brake fluid leaks. Repair any brake fluid leaks. 7. Adjust the J 29532 to 205 - 240 kPa (30 - 35 psi). Important: Use a shop cloth in order to catch escaping brake fluid. 8. Slowly open the ABS modulator brake pipe fitting (1) starting from the first pipe on the left side in order to allow the brake fluid to flow. Notice: Refer to Fastener Notice in Service Precautions. 9. Close the ABS modulator brake pipe fitting when air bubbles are no longer detected in the brake fluid. ^ Tighten the ABS modulator brake pipe fitting to 24 Nm (18 ft. lbs.). 10. Repeat Steps 8 and 9 for the remaining ABS modulator brake pipe fittings. 11. Raise and suitably support the vehicle. 12. Install the clear plastic bleeder hose to the RIGHT REAR bleeder valve: ^ For vehicles with rear drum brakes, install the clear plastic bleeder hose to the wheel cylinder bleeder valve. ^ For vehicles with rear disc brakes, install the clear plastic bleeder hose to the brake caliper bleeder valve. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 2525 13. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 14. Slowly open the bleeder valve in order to allow the brake fluid to flow. 15. Close the bleeder valve when air bubbles are no longer detected in the brake fluid. ^ For vehicles with rear drum brakes, tighten the wheel cylinder bleeder valve to 7 Nm (62 inch lbs.). ^ For vehicles with rear disc brakes, tighten the wheel cylinder bleeder valve to 11 Nm (97 inch lbs.) 16. Remove the clear plastic bleeder hose from the bleeder valve. 17. Install the clear plastic bleeder hose to the LEFT FRONT brake caliper bleeder valve. 18. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 19. Slowly open the bleeder valve in order to allow the brake fluid to flow. 20. Close the bleeder valve when air bubbles are no longer detected in the brake fluid. ^ Tighten the brake caliper bleeder valve to 13 Nm (115 inch lbs.). 21. Remove the clear plastic bleeder hose from the bleeder valve. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 2526 22. Install the clear plastic bleeder hose to the LEFT REAR bleeder valve. ^ For vehicles with rear drum brakes, install the clear plastic bleeder hose to the wheel cylinder bleeder valve. ^ For vehicles with rear disc brakes, install the clear plastic bleeder hose to the brake caliper bleeder valve. 23. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 24. Slowly open the bleeder valve in order to allow the brake fluid to flow. 25. Close the bleeder valve when air bubbles are no longer detected in the brake fluid. ^ For vehicles with rear drum brakes, tighten the wheel cylinder bleeder valve to 7 Nm (62 inch lbs.). ^ For vehicles with rear disc brakes, tighten the wheel cylinder bleeder valve to 11 Nm (97 inch lbs.) 26. Remove the clear plastic bleeder hose from the bleeder valve. 27. Install the clear plastic bleeder hose to the RIGHT FRONT brake caliper bleeder valve. 28. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 29. Slowly open the bleeder valve in order to allow the brake fluid to flow. 30. Close the bleeder valve when air bubbles are no longer detected in the brake fluid. ^ Tighten the brake caliper bleeder valve to 13 Nm (115 inch lbs.). 31. Remove the clear plastic bleeder hose from the bleeder valve. 32. Lower the vehicle. 33. Remove the J 35589 from the master cylinder reservoir. 34. Inspect and fill the master cylinder reservoir to the proper level as necessary. Refer to Master Cylinder Reservoir Filling. 35. Install the master cylinder reservoir cap. 36. Start the engine and allow the engine to run for at least 10 seconds. 37. Turn the ignition OFF. 38. Inspect the brake pedal feel and the brake pedal travel. Refer to Brake Pedal Travel. ^ If the brake pedal feels firm and constant and the brake pedal travel does not exceed specifications, proceed to Step 39. ^ If the pedal feels soft or the brake pedal travel exceeds specifications, DO NOT DRIVE THE VEHICLE. Go to Step 40. 39. Start the engine and inspect the brake pedal feel. ^ If the brake pedal still feels firm, got to Step 42. ^ If the brake pedal feels soft, DO NOT DRIVE THE VEHICLE. proceed to Step 40. 40. Use the scan tool in order to perform the automated bleed procedure. Refer to Automated Bleed Procedure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 2527 41. Ensure that the unacceptable brake pedal feel/travel is not caused by misadjusted brake linings or other mechanical failures, then repeat the Brake System Pressure Bleeding procedure. Proceed to Step 1. Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury. 42. Road test the vehicle. Make several normal (non-ABS) stops from a moderate speed in order to ensure proper brake system function. Allow adequate brake system cooling time between stops. Brake System Manual Bleeding Procedure Notice: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring, cables, or electric connectors. Brake fluid will damage the paint and the electrical connections. It any fluid is spilled on the vehicle, flush the area to lessen the damage. Important: This procedure may require the help of an assistant to apply the brake pedal while the bleeder valves are opened and closed. Important: Ensure that the master cylinder brake fluid level does not drop to the bottom of the master cylinder reservoir. You will be instructed to Inspect and fill the master cylinder reservoir at times during this procedure. However, the actual frequency of master cylinder reservoir filling REQUIRED will depend on the amount of fluid that is released. If the brake fluid level drops to the bottom of the master cylinder reservoir, start the bleed procedure again at Step 1. 1. Inspect and fill the master cylinder reservoir to the proper level as necessary. Refer to Master Cylinder Reservoir Filling. Important: Use a shop cloth in order to catch escaping brake fluid. 2. Slowly open the ABS modulator brake pipe fitting (1) starting from the first pipe on the left side in order to allow the brake fluid to flow. 3. Press and hold the brake pedal approximately 75 percent of a full stroke. Notice: Refer to Fastener Notice in Service Precautions. 4. Close the ABS modulator brake pipe fitting when air bubbles are no longer detected in the brake fluid. ^ Tighten the ABS modulator brake pipe fitting to 24 Nm (18 ft. lbs.). 5. Repeat Steps 2 and 3 for the remaining ABS modulator brake pipe fittings. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 2528 6. Inspect and fill the master cylinder reservoir to the proper level as necessary. 7. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 8. Install the clear plastic bleeder hose to the RIGHT REAR bleeder valve. ^ For vehicles with rear drum brakes, install the clear plastic bleeder hose to the wheel cylinder bleeder valve. ^ For vehicles with rear disc brakes, install the clear plastic bleeder hose to the brake caliper bleeder valve. 9. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 10. Open the bleeder valve. 11. Press and hold the brake pedal approximately 75 percent of a full stroke. 12. Close the bleeder valve. 13. Release the brake pedal. 14. Repeat Steps 10 through 13 until air bubbles are no longer detected in the brake fluid. ^ For vehicles with rear drum brakes, tighten the wheel cylinder bleeder valve to 7 Nm (62 inch lbs.). ^ For vehicles with rear disc brakes, tighten the wheel cylinder bleeder valve to 11 Nm (97 inch lbs.) 15. Remove the clear plastic bleeder hose from the bleeder valve. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 2529 16. Install the clear plastic bleeder hose to the LEFT FRONT brake caliper bleeder valve. 17. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 18. Open the bleeder valve. 19. Press and hold the brake pedal approximately 75 percent of a full stroke. 20. Close the bleeder valve. 21. Release the brake pedal. 22. Repeat Steps 18 through 21 until air bubbles are no longer detected in the brake fluid. ^ Tighten the brake caliper bleeder valve to 13 Nm (115 inch lbs.). 23. Remove the clear plastic bleeder hose from the bleeder valve. 24. Install the clear plastic bleeder hose to the LEFT REAR bleeder valve. ^ For vehicles with rear drum brakes, install the clear plastic bleeder hose to the wheel cylinder bleeder valve. ^ For vehicles with rear disc brakes, install the clear plastic bleeder hose to the brake caliper bleeder valve. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 2530 25. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 26. Open the bleeder valve. 27. Press and hold the brake pedal approximately 75 percent of a full stroke. 28. Close the bleeder valve. 29. Release the brake pedal. 30. Repeat Steps 26 through 29 until air bubbles are no longer detected in the brake fluid. ^ For vehicles with rear drum brakes, tighten the wheel cylinder bleeder valve to 7 Nm (62 inch lbs.). ^ For vehicles with rear disc brakes, tighten the wheel cylinder bleeder valve to 11 Nm (97 inch lbs.). 31. Remove the clear plastic bleeder hose from the bleeder valve. 32. Install the clear plastic bleeder hose to the RIGHT FRONT brake caliper bleeder valve. 33. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 34. Open the bleeder valve. 35. Press and hold the brake pedal approximately 75 percent of a full stroke. 36. Close the bleeder valve. 37. Release the brake pedal. 38. Repeat Steps 34 through 37 until air bubbles are no longer detected in the brake fluid. ^ Tighten the brake caliper bleeder valve to 13 Nm (115 inch lbs.). 39. Remove the clear plastic bleeder hose from the bleeder valve. 40. Lower the vehicle. 41. Remove the brake fluid reservoir cover. 42. Inspect the brake fluid level in the reservoir. 43. Install the brake fluid reservoir cover. 44. Turn the ignition switch to the RUN position, then turn off the engine. Apply the brake pedal with moderate force and hold the pedal. Note the pedal travel and feel. 45. If the pedal feels firm and constant and pedal travel is not excessive, start the engine. With the engine running, recheck the pedal travel. 46. If the pedal feel is still firm and constant and pedal travel is not excessive, perform a vehicle road test. Make several normal (non-ABS) stops from a moderate speed in order to ensure proper brake system function. 47. If pedal feel is soft or has excessive travel either initially or after engine start, refer to Automated Bleed Procedure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 2531 48. Repeat the manual bleeding procedure, starting at Step 1. Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury. 49. Perform a vehicle road test. Make several normal (non-ABS) stops from a moderate speed in order to ensure proper brake system function. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions CAUTION: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserve energy supply. The reserve energy supply provides deployment power for the air bags. Deployment power is available for as much as 10 seconds after disconnecting the vehicle power by any of the following methods: ^ Turn OFF the ignition. ^ Remove the fuse that provides power to the SDM. ^ Disconnect the vehicle battery from the vehicle electrical system. Disabling the SIR system prevents deploying of the air bags from the reserve energy supply power. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the LH instrument panel access hole cover. 5. Remove the SDM Fuse from the fuse block. IMPORTANT: With the SDM Fuse removed and the ignition ON, The AIR BAG warning lamp illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the RH instrument panel access hole cover. 7. Unclip the frontal air bags yellow 4-way connector from the metal rail. 8. Remove the Connector Position Assurance (CPA) from the frontal air bags yellow 4-way connector. 9. Disconnect the frontal air bags yellow 4-way connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 2537 10. Remove the connector position assurance (CPA) from the driver side air bag yellow 2-way connector (4) located under the driver seat, if the vehicle is equipped with a driver side air bag. 11. Disconnect the driver side air bag yellow 2-way connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 2538 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Connect the driver side air bag yellow 2-way connector (4) located under the driver seat, if the vehicle is equipped with a driver side air bag. 2. Install the CPA to the driver side air bag yellow 2-way connector. 3. Connect the frontal air bags yellow 4-way connector located at the RH side of the instrument panel. 4. Install the CPA to the frontal air bags yellow 4-way connector. 5. Connect the frontal air bags yellow 4-way connector to the metal rail. 6. Instal the RH instrument panel access hole cover. 7. Install the SDM fuse to the LH fuse block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 2539 8. Install the LH instrument panel access hole cover. 9. Staying well away from the airbags, turn ON the ignition. 9.1. The AIR BAG warning lamp will flash seven times. 9.2. The AIR BAG warning lamp will then turn OFF. 10. Perform A Diagnostic System Check SIR if the AIR BAG warning lamp does not operate as described. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations Fuse Block: Component Locations Accessory Wiring Junction Block, LH LH side of the instrument panel, in the left front door opening. Bottom Underhood Accessory Wiring Junction Block RH side of the engine compartment, forward of the strut tower. Engine Wiring Harness Junction Block (Top) RH side of the engine compartment, forward of the strut tower. Instrument Panel Fuse Block, LH Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2549 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2550 Locations View RPO 9C1/9C6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Instrument Panel Fuse Block, RH Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2551 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2552 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2553 Locations View RPO 9C1/9C6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2554 Locations View SEO Fuse Relay Block RH upper side of the steering column, above the knee bolster. Top Underhood Accessory Wiring Junction Block RH side of the engine compartment, forward of the strut tower. Underhood Accessory Wiring Junction Block Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2555 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2556 Locations View RPO 9C1/9C6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2557 Locations View Wiring Harness Junction Block (SEO) Mounted on the RH side of the rear compartment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2558 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) Fuse Block (SEO) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 2561 Fuse Block: Diagrams LH IP Accessory Wiring Junction Block, C1 LH IP Accessory Wiring Junction Block, C1 (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 2562 LH IP Accessory Wiring Junction Block, C1 (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 2563 Fuse Block: Diagrams LH IP Accessory Wiring Junction Block, C3 LH IP Accessory Wiring Junction Block, C3 (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 2564 LH IP Accessory Wiring Junction Block, C3 (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 2565 Fuse Block: Diagrams RH IP Accessory Wiring Junction Block, C1 RH IP Accessory Wiring Junction Block, C1 (Part 1 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 2566 RH IP Accessory Wiring Junction Block, C1 (Part 2 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 2567 RH IP Accessory Wiring Junction Block, C1 (Part 3 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 2568 Fuse Block: Diagrams RH IP Accessory Wiring Junction Block, C3 RH IP Accessory Wiring Junction Block, C3 (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 2569 RH IP Accessory Wiring Junction Block, C3 (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks Fuse Block: Application and ID Instrument Panel Fuse Blocks Instrument Panel Fuse Block, LH Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 2572 Instrument Panel Fuse Block, RH Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 2573 LH Instrument Panel Fuse Block Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 2574 LH Instrument Panel Fuse Block, Top View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 2575 LH Instrument Panel Fuse Block, Bottom View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 2576 RH Instrument Panel Fuse Block Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 2577 RH Instrument Panel Fuse Block, Top View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 2578 RH Instrument Panel Fuse Block, Bottom View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 2579 Fuse Block: Application and ID Electrical Centers Top Underhood Electrical Center Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 2580 Top Underhood Electrical Center, Top View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 2581 Top Underhood Electrical Center, Bottom View Bottom Underhood Electrical Center Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 2582 Bottom Underhood Electrical Center, Top View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 2583 Bottom Underhood Electrical Center, Bottom View Underhood Electrical Center, Top Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 2584 Underhood Electrical Center, Bottom Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Relay/Fuse Center Replacement (Left) Fuse Block: Service and Repair Relay/Fuse Center Replacement (Left) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Adjust the instrument panel (IP) cluster trim plate for access. 3. Disconnect the body wiring harness from the junction block. 4. Remove the junction block bolts. 5. Remove the junction block tab from the slot in the cross vehicle beam. Pull the junction block away from the IP. 6. Disconnect the body wiring harness from the junction block. 7. Remove the junction block. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Relay/Fuse Center Replacement (Left) > Page 2587 1. Connect the body wiring harness to the junction block. 2. Install the junction block tab to the slot in the cross vehicle beam. 3. Install the junction block bolts. Tighten Tighten the junction block bolts to 10 N.m (89 lb in). 4. Connect the body wiring harness to the junction block. Tighten Tighten the body wiring harness connector bolt to 7 N.m (62 lb in). 5. Install the instrument panel (IP) cluster trim plate. 6. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Relay/Fuse Center Replacement (Left) > Page 2588 Fuse Block: Service and Repair Relay/Fuse Center Replacement (Right) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the RH instrument panel (IP) fuse block access opening cover. 3. Remove the IP compartment. 4. Disconnect the body wiring harness from the junction block. 5. Remove the junction block bolt. 6. Disengage the junction block tabs from the passenger knee bolster. Pull the junction block away from the IP. 7. Disconnect the wiring harnesses from the junction block. 8. Remove the junction block. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Relay/Fuse Center Replacement (Left) > Page 2589 1. Connect the body wiring harnesses to the junction block. Tighten Tighten the body wiring harness connector bolts to 7 N.m (62 lb in). 2. Install the junction block tabs to the passenger knee bolster. 3. Install the junction block bolt. Tighten Tighten the junction block bolt to 10 N.m (89 lb in). 4. Connect the body wiring harness to the junction block. 5. Install the instrument panel (IP) compartment. 6. Install the RH IP fuse block access opening cover. 7. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fusible Links, IP Harness Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Locations Low Tire Pressure Indicator: Locations Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Locations > Page 2598 Component Locator Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions Low Tire Pressure Indicator: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2601 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2602 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2603 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2604 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2605 Low Tire Pressure Indicator: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2606 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2607 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2608 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2609 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2610 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2611 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2612 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2613 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2614 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2615 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2616 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2617 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2618 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2619 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2620 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2621 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2622 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2623 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2624 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2625 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2626 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2627 Low Tire Pressure Indicator: Electrical Diagrams Schematic and Routing Diagrams Tire Pressure Monitoring System Schematics (EBCM, Power, Ground and Instrument Cluster) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2628 Tire Pressure Monitoring System Schematics (Wheel Speed Sensors) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2629 Tire Pressure Monitoring System Schematics: EBCM, Power, Ground And Instrument Cluster Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2630 Tire Pressure Monitoring System Schematics: Wheel Speed Sensors Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation > Low Tire Pressure Warning System (LTPWS) Low Tire Pressure Indicator: Description and Operation Low Tire Pressure Warning System (LTPWS) Tire Inflation Monitoring System Operation The tire pressure monitor (TPM) system alerts the driver when the pressure changes in one of the tires. The system only detects a low pressure condition while the vehicle is being driven. Once a low tire pressure condition is detected, the system informs the driver whenever the ignition is ON. The LOW TIRE PRESSURE indicator illuminates if the tire pressure in one or more tires become at least 52 kPa (12 psi) lower or higher than the other tires. The message does not appear if the system is not calibrated properly. The system does not inform the driver which tire is low. To clear this message., set the tire pressures in all four tires to the proper pressures and perform the system reset procedure. Refer to Tire Inflation Monitor Reset Procedure for service procedure. See: Wheels and Tires/Tire Monitoring System/Testing and Inspection The Tire Pressure Monitor software requires approximately One half hour of straight line driving to complete the TPM autolearn. There 'are several speed ranges' that the EBCM needs to learn the tire inflation configuration in order to have the full capability of detecting a low tire condition. The speed detection ranges are the following: ^ 24~64 km/h (15-40 mph) ^ 64-113km/h (40-70 mph) ^ 113-145 km/h (7O~90 mph) Each speed range has 2 modes of low tire detection. ^ Monitor Mode 1 ^ Monitor Mode 2 The, EBCM learns the tire inflation configuration for each speed range independently. In Monitor Mode 1, the EBCM has only partially learned the tire inflation configuration for the speed range and has limited detection capability for a low tire condition. In Monitor Mode 2, the EBCM has fully learned the tire inflation configuration for the speed range and has full detection capability for a low tire condition. If the EBCM is not in Monitor Mode 1 or Monitor Mode 2, a low tire condition cannot be detected because the EBCM has not learned the tire inflation configuration of the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation > Low Tire Pressure Warning System (LTPWS) > Page 2633 Low Tire Pressure Indicator: Description and Operation Tire Inflation Monitoring System Operation The tire pressure monitor (TPM) system alerts the driver when the pressure changes in one of the tires. The system only detects a low pressure condition while the vehicle is being driven. Once a low tire pressure condition is detected, the system informs the driver whenever the ignition is ON. The LOW TIRE PRESSURE indicator illuminates if the tire pressure in one or more tires become at least 82 kPa (12 psi) lower or higher than the other tires. The message does not appear if the system is not calibrated properly. The system does not inform the driver which tire is low. To clear this message, set the tire pressures in all four tires to the proper pressures and perform the system reset procedure. Refer to Tire Inflation Monitor Reset Procedure for service procedure. The Tire Pressure Monitor software requires approximately one half hour of straight line driving to complete the TPM auto-learn. There are several speed ranges that the EBCM needs to learn the tire inflation configuration in order to have the full capability of detecting a low tire condition. The speed detection ranges are the following: ^ 24-64 km/h (15-40 mph) ^ 64-113 km/h (40-70 mph) ^ 113-145 km/h (70-90 mph) Each speed range has 2 modes of low tire detection. ^ Monitor Mode 1 ^ Monitor Mode 2 The EBCM learns the tire inflation configuration for each speed range independently. In Monitor Mode 1, the EBCM has only partially learned the tire inflation configuration for the speed range and has limited detection capability for a low tire condition. In Monitor Mode 2, the EBCM has fully learned the tire inflation configuration for the speed range and has full detection capability for a low tire condition. If the EBCM is not in Monitor Mode 1 or Monitor Mode 2, a low tire condition cannot be detected because the EBCM has not learned the tire inflation configuration of the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Malfunction Indicator Lamp: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2638 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2639 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2640 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2641 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2642 Malfunction Indicator Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2643 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2644 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2645 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2646 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2647 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2648 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2649 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2650 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2651 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2652 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2653 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2654 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2655 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2656 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2657 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2658 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2659 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2660 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2661 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2662 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2663 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 2664 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Malfunction Indicator Lamp (MIL) - Description Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) Description The Service Engine Soon/Malfunction Indicator Lamp (MIL) is located in the Instrument Panel (IP) Cluster. The MIL is controlled by the PCM and is used to indicate that the PCM has detected a condition that affects vehicle emissions, may cause powertrain damage, or severely impacts driveability. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Malfunction Indicator Lamp (MIL) - Description > Page 2667 Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) Operation The Malfunction Indicator Lamp (MIL) is located on the instrument panel and is displayed as CHECK ENGINE lamp. MIL Function ^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible ^ The MIL illuminates during a bulb test and a system test ^ A DTC will be stored if a MIL is requested by the diagnostic MIL Illumination ^ The MIL will illuminate with ignition ON and the engine OFF ^ The MIL will turn OFF when the engine is started ^ The MIL will remain ON if the self-diagnostic system has detected a malfunction ^ The MIL may turn OFF if the malfunction is not present ^ If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. ^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2668 Malfunction Indicator Lamp: Service and Repair SERVICE ENGINE SOON INDICATOR If this light is on, it indicates a problem in one of the electronically monitored systems. This light does NOT come on at certain mileage intervals. There is probably a Engine Control Module (ECM) or a Body Control Module (BCM) Code set that will aid you in diagnosis. Reset Procedure The only way to get the light to go off is to clear the ECM or BCM code(s). This light can NOT be reset or shut off any other way. ECM/BCM codes should be read & repaired before clearing them. SERVICE VEHICLE SOON INDICATOR If this light is on, it indicates a problem in one of the electronically monitored systems (a non-emissions related powertrain malfunction). This light does NOT come on at certain mileage intervals. There is probably a Engine Control Module (ECM) or a Body Control Module (BCM) Code set that will aid you in diagnosis. Reset Procedure The only way to get the light to go off is to clear the ECM or BCM code(s). This light can NOT be reset or shut off any other way. ECM/BCM codes should be read & repaired before clearing them. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation Oil Change Reminder Lamp: Description and Operation GM OIL LIFE SYSTEM If the vehicle is equipped with a GM Oil Life System, this feature will let you know when to change the oil and filter - usually between 3,000 miles (5 000 km) and 7,500 miles (12 500 km) since your last oil change. Under severe conditions, the indicator may come on before 3,000 miles (5 000 km). Never drive the vehicle more than 12 500 km (7,500 miles) or 12 months, (whichever occurs first), without an oil change. The GM Oil Life System will not detect dust in the oil. If the vehicle is driven in a dusty area, be sure to change the oil every 5 000 km (3,000 miles) or sooner if the "CHANGE OIL" or "CHANGE OIL SOON" message is displayed. To reset the GM Oil Life System, refer to Service and Repair. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 2672 Oil Change Reminder Lamp: Service and Repair GM Oil Life System Resetting Resetting Procedure Follow this procedure to reset the GM Oil Life System (TM) 1. Turn the ignition to ON without starting the engine. 2. Fully press and release the accelerator pedal three times within five seconds. If the CHG OIL SOON indicator flashes two times, the system is resetting. 3. Turn the key to OFF, then start the vehicle. If the CHG OIL SOON light comes back on, the system has not reset, repeat the procedure Follow this procedure to reset the GM Oil Life System (TM) using the DE 100 Series Radio (R) 1. Turn the ignition to ACC or ON and the radio off. 2. Press and hold the DISP button on the radio for at least five seconds until SETTINGS is displayed. 3. Press the SEEK up or down arrow to scroll though the main menu 4. Scroll until OIL LIFE appears on the display. 5. Press the PREV or NEXT button to enter the submenu. RESET will be displayed. 6. Press the DISP button to reset. A chime will be heard to verify the new setting and DONE will be displayed for one second. 7. Once the message has been reset, scroll until EXIT appears on the display. 8. Press the DISP button to exit programming. A chime will be heard to verify the exit. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Description and Operation Oil Level Warning Indicator: Description and Operation Engine Oil Level Switch The PCM monitors the engine oil level switch signal at start-up to determine if the engine oil is OK. If the PCM determines that a low oil level condition exists, the PCM will communicate the information over the Class II circuit to the P cluster and it will illuminate the indicator lamp or initiate a message. The low oil level message may not appear if other messages are being commanded, such as the rear deck lid, driver or passenger doors ajar. Ensure that all doors and compartment lids are completely closed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Locations Low Tire Pressure Indicator: Locations Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Locations > Page 2691 Component Locator Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions Low Tire Pressure Indicator: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2694 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2695 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2696 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2697 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2698 Low Tire Pressure Indicator: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2699 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2700 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2701 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2702 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2703 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2704 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2705 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2706 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2707 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2708 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2709 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2710 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2711 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2712 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2713 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2714 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2715 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2716 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2717 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2718 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2719 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2720 Low Tire Pressure Indicator: Electrical Diagrams Schematic and Routing Diagrams Tire Pressure Monitoring System Schematics (EBCM, Power, Ground and Instrument Cluster) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2721 Tire Pressure Monitoring System Schematics (Wheel Speed Sensors) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2722 Tire Pressure Monitoring System Schematics: EBCM, Power, Ground And Instrument Cluster Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2723 Tire Pressure Monitoring System Schematics: Wheel Speed Sensors Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Low Tire Pressure Warning System (LTPWS) Low Tire Pressure Indicator: Description and Operation Low Tire Pressure Warning System (LTPWS) Tire Inflation Monitoring System Operation The tire pressure monitor (TPM) system alerts the driver when the pressure changes in one of the tires. The system only detects a low pressure condition while the vehicle is being driven. Once a low tire pressure condition is detected, the system informs the driver whenever the ignition is ON. The LOW TIRE PRESSURE indicator illuminates if the tire pressure in one or more tires become at least 52 kPa (12 psi) lower or higher than the other tires. The message does not appear if the system is not calibrated properly. The system does not inform the driver which tire is low. To clear this message., set the tire pressures in all four tires to the proper pressures and perform the system reset procedure. Refer to Tire Inflation Monitor Reset Procedure for service procedure. See: Testing and Inspection The Tire Pressure Monitor software requires approximately One half hour of straight line driving to complete the TPM autolearn. There 'are several speed ranges' that the EBCM needs to learn the tire inflation configuration in order to have the full capability of detecting a low tire condition. The speed detection ranges are the following: ^ 24~64 km/h (15-40 mph) ^ 64-113km/h (40-70 mph) ^ 113-145 km/h (7O~90 mph) Each speed range has 2 modes of low tire detection. ^ Monitor Mode 1 ^ Monitor Mode 2 The, EBCM learns the tire inflation configuration for each speed range independently. In Monitor Mode 1, the EBCM has only partially learned the tire inflation configuration for the speed range and has limited detection capability for a low tire condition. In Monitor Mode 2, the EBCM has fully learned the tire inflation configuration for the speed range and has full detection capability for a low tire condition. If the EBCM is not in Monitor Mode 1 or Monitor Mode 2, a low tire condition cannot be detected because the EBCM has not learned the tire inflation configuration of the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Low Tire Pressure Warning System (LTPWS) > Page 2726 Low Tire Pressure Indicator: Description and Operation Tire Inflation Monitoring System Operation The tire pressure monitor (TPM) system alerts the driver when the pressure changes in one of the tires. The system only detects a low pressure condition while the vehicle is being driven. Once a low tire pressure condition is detected, the system informs the driver whenever the ignition is ON. The LOW TIRE PRESSURE indicator illuminates if the tire pressure in one or more tires become at least 82 kPa (12 psi) lower or higher than the other tires. The message does not appear if the system is not calibrated properly. The system does not inform the driver which tire is low. To clear this message, set the tire pressures in all four tires to the proper pressures and perform the system reset procedure. Refer to Tire Inflation Monitor Reset Procedure for service procedure. The Tire Pressure Monitor software requires approximately one half hour of straight line driving to complete the TPM auto-learn. There are several speed ranges that the EBCM needs to learn the tire inflation configuration in order to have the full capability of detecting a low tire condition. The speed detection ranges are the following: ^ 24-64 km/h (15-40 mph) ^ 64-113 km/h (40-70 mph) ^ 113-145 km/h (70-90 mph) Each speed range has 2 modes of low tire detection. ^ Monitor Mode 1 ^ Monitor Mode 2 The EBCM learns the tire inflation configuration for each speed range independently. In Monitor Mode 1, the EBCM has only partially learned the tire inflation configuration for the speed range and has limited detection capability for a low tire condition. In Monitor Mode 2, the EBCM has fully learned the tire inflation configuration for the speed range and has full detection capability for a low tire condition. If the EBCM is not in Monitor Mode 1 or Monitor Mode 2, a low tire condition cannot be detected because the EBCM has not learned the tire inflation configuration of the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair Spare Tire: Service and Repair The compact spare uses a narrow 4-inch wide rim. The wheel diameter is usually one inch larger than the road wheels. Do not use standard tires or snow tires on a compact spare wheel or damage to the vehicle may result. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause serious personal injury. Periodically check the inflation pressure of the compact spare and maintain this pressure at 415 kPa (60 psi). Use the present tire changing equipment and procedures to mount and dismount the compact tire from its wheel. As with other tires, the beads should completely seat at 275 kPa (40 psi). You may then safely inflate the spare tire to 415 kPa (60 psi). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2747 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2748 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2749 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 2754 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2759 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2760 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2765 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2766 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2767 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 2772 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2777 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2778 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2779 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2789 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2790 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2791 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 2796 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2801 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2802 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2803 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2809 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2810 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2811 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 2816 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2821 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2822 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2827 Wheels: Service Precautions Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. Remove and install the tire over the curb-side bead seat. Machines which do not have a flat bed for the wheel to rest may cause cosmetic damage when the wheel is being clamped down. The bottom bead breaker on some machines may also cause cosmetic damage. Most tire changing equipment manufacturers have aluminum wheel adapter kits and plastic or Teflon(R) coated tools which will prevent cosmetic damage. Even with these kits you must modify some machines. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2828 Wheels: Testing and Inspection Notice: The use of non-GM original equipment wheels may cause: ^ Damage to the wheel bearing, the wheel fasteners and the wheel ^ Tire damage caused by the modified clearance to the adjacent vehicle components ^ Adverse vehicle steering stability caused by the modified scrub radius ^ Damage to the vehicle caused by the modified ground clearance ^ Speedometer and odometer inaccuracy Important: Replacement wheels must be equivalent to the original equipment wheels in load capacity, diameter, rim width, offset and mounting configuration. A wheel of improper size or type may affect the wheel and bearing life, the brake cooling, the speedometer/odometer calibration, the vehicle ground clearance and the tire clearance to the body and the chassis. Replace wheels under the following conditions: ^ The wheels are bent or dented ^ The wheels have excessive radial runout ^ The wheels leak air through the wheel welds ^ The wheels have elongated bolt holes ^ The wheel nuts do not stay tight ^ The wheels are very rusty Wheels with excessive runout may cause objectionable vibrations. Steel wheels are identified by a two or three letter code stamped into the rim near the valve stem. Aluminum wheels have the code, part number, and manufacturer ID cast into their back side. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Repair Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation. 3. Use the following procedure to locate the leaking areas: ^ Inflate the tire to 275 kPa (40 psi). ^ Dip the tire and wheel into a water bath. 4. Mark the leak areas. 5. Remove the tire from the wheel. 6. Use 80 grit sandpaper to scuff the inside surface at the leak area. 7. Use a general purpose cleaner such as 3M #08984 or equivalent to clean the area. 8. Apply a 1/8-inch thick layer of adhesive sealant GM P/N 1052366 or equivalent to the leak area. 9. Allow 12 hours of drying time. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause serious personal injury. 1. Install the tire on the wheel. 2. Pressurize to 275 kPa (40 psi). 3. Inspect for leaks. 4. Adjust the tire pressure in order to meet the specifications. Refer to Tire Inflation Pressure Specifications. 5. Balance the tire and wheel assembly. Refer to Vibration Diagnosis and Correction under Steering and Suspension Testing and Inspection. 6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation. 7. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 2831 Wheels: Service and Repair Aluminum Wheel Refinishing A protective clear coat and/or base color coats the surface of the original equipment cast aluminum wheels. Surface degradation may develop from the use of wrong balance weights. Frequent, repeated automatic car wash cleaning from facilities using aggressive silicon carbide tipped tire brushes for cleaning whitewalls and tires may also damage the finish. Once the protective clear coat is damaged, exposure to caustic cleaners and/or road salt causes further surface degradation. The refinishing of aluminum wheels requires that the wheel surface be plastic media blasted in order to remove old clear coat or paint. The re-machining or the use of chemical strippers is not recommended due to concerns of repair durability. The service procedure details how to strip, clean and recoat aluminum wheel rims that are affected by the above condition. Required Materials You may use three different paint systems to refinish aluminum wheels. These products have shown the required repair durability. These products are the only paint systems that meet General Motors specification 4350M-A336. ^ System 1: Dupont Products ^ System 2: PPG Products ^ System 3: Spies Hecker Color Selection If the wheels being painted were previously clear coated aluminum, the use of Corsican SILVER WAEQ9283 for a fine aluminum-like look or Sparkle SILVER WA9967 for a very bright look is recommended. Refer to the paint manufacturer's color book for body color selection and verification. Refinish all four wheels and their center caps to ensure color uniformity. Important: Refer to and follow the individual formula and process which the manufacturer of each specific paint system provides. Use the products listed as a system only. Do not mix other manufacturers' product lines with the required materials of a given system. The products listed in this manual have shown the required repair durability. These products are the only paint systems that meet General Motors specification 435M-A336. Repair Procedure Caution: To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 1. Remove the wheels from the vehicle. Refer to Tire and Wheel Removal and Installation. Keep the tires mounted on the wheels. 2. Mark the location of the weights on the tire. 3. Remove the balance weights. 4. Record the value of each weight for reinstallation. 5. Use wax and grease remover to wipe any excess grease and/or dirt from the wheels. Important: The re-machining of aluminum wheels or the use of chemical strippers is not recommended due to concerns of durability. 6. Blast the wheels with plastic media in order to remove old paint or clear coat. 7. Mask off the wheels and tires. 8. Refer to and follow the individual painting formula and process provided by the manufacturer of each specific paint system. 9. Unmask the wheels and tires. 10. Install the new coated balance weights at the locations marked on the tires. 11. Clean all wheel mounting surfaces of any corrosion, overspray or dirt. Install the wheels to the vehicle. Refer to Tire and Wheel Removal and Installation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 2832 Wheels: Service and Repair Steel Wheel Repair Wheel repairs that use welding, heating, or peening are not approved. An inner tube is not an acceptable repair for leaky wheels or tires. If a steel wheel is found to be leaking, replace the wheel with one of original equipment quality. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use GC Wheel Bearing Grease. GC ....................................................................................................................................................... ............. Wheel Bearing Grease, NLGI Classification Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement Wheel Bearing: Service and Repair Front Wheel Drive Shaft Bearing Replacement Front Wheel Drive Shaft Bearing Replacement Removal Procedure Tools Required ^ J 28733-B Spindle Remover 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Disconnect the wheel speed sensor electrical connector (2). 4. Remove the wheel speed sensor electrical connector from the bracket. 5. Remove the brake caliper bracket with the brake caliper. Refer to Brake Caliper Bracket Replacement (Front) or Brake Caliper Bracket Replacement (Rear) in Brakes and Traction Control. 6. Remove the brake rotor. Refer to Brake Rotor Replacement (Front) or Brake Rotor Replacement (Rear) in Brakes and Traction Control. 7. Remove the wheel drive shaft nut. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement > Page 2838 8. Use three wheel nuts in order to attach the J 28733-B to the wheel bearing/hub. 9. Use the J 28733-B in order to push the wheel drive shaft out of the wheel bearing/hub. 10. Remove and DISCARD the wheel bearing/hub bolts. Important: Ensure that the wheel drive shaft outer seal (boot) is not damaged. 11. Remove the wheel bearing/hub. Installation Procedure 1. Install the wheel bearing/hub. Caution: These fasteners MUST be replaced with new fasteners anytime they become loose or are removed. Failure to replace these fasteners after they become loose or are removed may cause loss of vehicle control and personal injury. Notice: Refer to Fastener Notice in Service Precautions Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement > Page 2839 2. Install NEW wheel bearing/hub bolts. Tighten the NEW wheel bearing/hub bolts to 130 Nm (96 ft. lbs.). 3. Install the wheel drive shaft nut. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts. 4. Install the brake rotor. Refer to Brake Rotor Replacement (Front) or Brake Rotor Replacement (Rear) in Brakes and Traction Control. 5. Install the brake caliper bracket with the brake caliper. Refer to Brake Caliper Bracket Replacement (Front) or Brake Caliper Bracket Replacement (Rear) in Brakes and Traction Control. Important: Ensure that the connector clip engages the bracket properly. 6. Install the wheel speed sensor electrical connector to the bracket. 7. Connect the wheel speed sensor electrical connector (2). 8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 9. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement > Page 2840 Wheel Bearing: Service and Repair Wheel Bearing/Hub Replacement-Rear Wheel Bearing/Hub Replacement - Rear Removal Procedure The wheel bearing in the rear wheel hub is integrated into one unit. The hub is non-serviceable. If the hub and/or bearing is damaged, replace the complete hub and bearing assembly. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tires and wheels. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Remove the rear caliper and bracket. Refer to Brake Caliper Bracket Replacement (Rear) in Disc Brakes. 4. Remove the brake rotor. Refer to Brake Rotor Replacement (Rear) in Disc Brakes. 5. Disconnect the ABS electrical connector from the wheel speed sensor (1). Refer to Wheel Speed Sensor Replacement (Rear) in Antilock Brakes. 6. Remove the rear wheel hub-to-knuckle bolts. 7. Remove the rear wheel hub and park brake assembly from the knuckle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement > Page 2841 8. Remove the parking brake lever bracket (8). 9. Remove the parking brake actuator (6). Installation Procedure 1. Install the parking brake lever bracket (8). 2. Install the parking brake actuator (6). 3. Install the rear wheel hub and park brake assembly to the knuckle. Notice: Refer to Fastener Notice in Service Precautions. 4. Install new rear wheel hub-to-knuckle bolts. Tighten the hub mounting bolts to 75 Nm (55 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement > Page 2842 5. Connect the ABS electrical connector to the wheel speed sensor (1). Refer to Wheel Speed Sensor Replacement (Rear) in Antilock Brakes. 6. Install the brake rotor. Refer to Brake Rotor Replacement (Rear) in Disc Brakes. 7. Install the rear caliper and bracket. Refer to Brake Caliper Bracket Replacement (Rear) in Disc Brakes. 8. Install the tires and wheels. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 9. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair Wheel Cover: Service and Repair Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation. 3. Place a squared off block of wood approximately 50 mm (2 inch) diameter against the back surface of the cap. 4. Use a hammer to strike the block of wood to remove the cap. Installation Procedure Notice: Failure to hit the cap squarely without the load distributed evenly could result in permanent damage to the cap. 1. Place the cap into position at the wheel opening. 2. Place a block of wood at least 76 mm (3 inch) diameter against the cap face. 3. Use a hammer to strike the block of wood to install the cap. 4. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation. 5. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Wheel Drive Shaft Nut 159 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 2858 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 2864 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99-03-10-103 > Oct > 99 > Wheels - Stud Removal Tool Change Wheel Fastener: All Technical Service Bulletins Wheels - Stud Removal Tool Change File In Section: 03 - Suspension Bulletin No.: 99-03-10-103 Date: October, 1999 INFORMATION Subject: Discontinue Usage of Tool J 6627-A for Wheel Stud Removal Models: 1992-99 Buick Riviera 1992-2000 Buick Century, LeSabre, Park Avenue, Regal 1992-2000 Cadillac DeVille, Eldorado, Seville 1992-96 Chevrolet Lumina APV 1997 Chevrolet Corvette (C-5) 1997-2000 Chevrolet Venture 2000 Chevrolet Impala, Monte Carlo 1992-99 Oldsmobile Aurora, Eighty Eight, Regency 1992-2000 Oldsmobile Silhouette 1998-2000 Oldsmobile Intrigue 1992-98 Pontiac Trans Sport 1992-2000 Pontiac Bonneville, Grand Prix 1999-2000 Pontiac Montana SPECIAL TOOL J 6627-A IS NOT TO BE USED AS THE WHEEL STUD REMOVAL TOOL FOR THE ABOVE VEHICLES. Notice: The fingers of J 6627-A extend too far down the back of the wheel hub and bearing assembly. When this tool is used as a wheel stud press, it may cause damage to the wheel hub inner seal. If the seal is damaged, water intrusion may occur and the life span of the wheel hub and bearing assembly may be decreased. Important: If any seal is damaged, it is recommended that the wheel hub and bearing assembly be replaced. USE OF EITHER SPECIAL TOOL J 35917 OR J 43631 IS RECOMMENDED IN ORDER TO PROPERLY REMOVE THE WHEEL STUDS ON THE VEHICLES LISTED ABOVE. These tools have similar dimensions and differ slightly in appearance, therefore, only one illustration is included. Notice: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99-03-10-103 > Oct > 99 > Wheels - Stud Removal Tool Change > Page 2869 Do not remove the wheel studs with a hammer. This technique can potentially damage the wheel hub and bearing assembly. In addition to using special tool J 35917 or J 43631, the following vehicles require the front wheel hub bearing to be removed from the front aluminum knuckle in order to replace the wheel stud: - 1995-99 Buick Riviera - 1997-2000 Buick Century, Park Avenue Regal - 2000 Buick LeSabre - 1997-2000 Cadillac DeVille, Eldorado, Seville - 1997 Chevrolet Corvette (C-S) - 1997-2000 Chevrolet Venture - 2000 Chevrolet Impala, Monte Carlo - 1995-99 Oldsmobile Aurora - 1997-2000 Oldsmobile Silhouette - 1998-2000 Oldsmobile Intrigue - 1997-98 Pontiac Trans Sport - 1997-2000 Pontiac Grand Prix - 1999-2000 Pontiac Montana - 2000 Pontiac Bonneville Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 99-03-10-103 > Oct > 99 > Wheels - Stud Removal Tool Change Wheel Fastener: All Technical Service Bulletins Wheels - Stud Removal Tool Change File In Section: 03 - Suspension Bulletin No.: 99-03-10-103 Date: October, 1999 INFORMATION Subject: Discontinue Usage of Tool J 6627-A for Wheel Stud Removal Models: 1992-99 Buick Riviera 1992-2000 Buick Century, LeSabre, Park Avenue, Regal 1992-2000 Cadillac DeVille, Eldorado, Seville 1992-96 Chevrolet Lumina APV 1997 Chevrolet Corvette (C-5) 1997-2000 Chevrolet Venture 2000 Chevrolet Impala, Monte Carlo 1992-99 Oldsmobile Aurora, Eighty Eight, Regency 1992-2000 Oldsmobile Silhouette 1998-2000 Oldsmobile Intrigue 1992-98 Pontiac Trans Sport 1992-2000 Pontiac Bonneville, Grand Prix 1999-2000 Pontiac Montana SPECIAL TOOL J 6627-A IS NOT TO BE USED AS THE WHEEL STUD REMOVAL TOOL FOR THE ABOVE VEHICLES. Notice: The fingers of J 6627-A extend too far down the back of the wheel hub and bearing assembly. When this tool is used as a wheel stud press, it may cause damage to the wheel hub inner seal. If the seal is damaged, water intrusion may occur and the life span of the wheel hub and bearing assembly may be decreased. Important: If any seal is damaged, it is recommended that the wheel hub and bearing assembly be replaced. USE OF EITHER SPECIAL TOOL J 35917 OR J 43631 IS RECOMMENDED IN ORDER TO PROPERLY REMOVE THE WHEEL STUDS ON THE VEHICLES LISTED ABOVE. These tools have similar dimensions and differ slightly in appearance, therefore, only one illustration is included. Notice: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 99-03-10-103 > Oct > 99 > Wheels - Stud Removal Tool Change > Page 2875 Do not remove the wheel studs with a hammer. This technique can potentially damage the wheel hub and bearing assembly. In addition to using special tool J 35917 or J 43631, the following vehicles require the front wheel hub bearing to be removed from the front aluminum knuckle in order to replace the wheel stud: - 1995-99 Buick Riviera - 1997-2000 Buick Century, Park Avenue Regal - 2000 Buick LeSabre - 1997-2000 Cadillac DeVille, Eldorado, Seville - 1997 Chevrolet Corvette (C-S) - 1997-2000 Chevrolet Venture - 2000 Chevrolet Impala, Monte Carlo - 1995-99 Oldsmobile Aurora - 1997-2000 Oldsmobile Silhouette - 1998-2000 Oldsmobile Intrigue - 1997-98 Pontiac Trans Sport - 1997-2000 Pontiac Grand Prix - 1999-2000 Pontiac Montana - 2000 Pontiac Bonneville Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Torque Wheel Fastener: Specifications Wheel Fastener Torque Wheel Fastener Torque Wheel Fastener 100 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Torque > Page 2878 Lug Nut Torque Patterns Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 2879 Wheel Fastener: Description and Operation Metric wheel nuts have the word Metric stamped on the face. The letter M is stamped at the end of the metric wheel stud. Thread size of the metric wheel nuts and studs is indicated by the following example: M12 x 1.5 ^ M = Metric ^ 12 = Diameter in millimeters ^ 1.5 = Millimeters per thread (gap between) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 2880 Wheel Fastener: Service and Repair Removal Procedure Tools Required ^ J 35917 Wheel Bolt Remover 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Remove the brake caliper and bracket. Refer to Brake Caliper Bracket Replacement (Front) or Brake Caliper Bracket Replacement (Rear) in Disc Brakes. 4. Remove the rotor (3). Refer to Brake Rotor Replacement (Front) or Brake Rotor Replacement (Rear) in Disc Brakes. 5. Use the J 35917 (2) to extract the wheel hub bolt from the hub (1). 6. Clean the wheel hub flange and clean the rotor of any corrosion, metal chips or foreign material. Installation Procedure 1. Install the replacement bolt in the wheel hub (1). 2. Add enough washers to draw the bolt into the hub. Important: Seat the wheel bolt fully against the hub flange. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the wheel nut with the flat side to the washers. Tighten the wheel nut until the wheel bolt head seats against the hub flange. 4. Back off the wheel nut. 5. Remove the washers. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 2881 6. Install the rotor (3). Refer to Brake Rotor Replacement (Front) or Brake Rotor Replacement (Rear) in Disc Brakes. 7. Install the brake caliper. Refer to Brake Caliper Bracket Replacement (Front) or Brake Caliper Bracket Replacement (Rear) in Disc Brakes. 8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 9. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 2882 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions > Technician Safety Information Jump Starting: Technician Safety Information CAUTION: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions: - Air bag deployment - Personal injury - Unnecessary SIR system repairs In order to avoid the above conditions, observe the following guidelines: - Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring. - If you are performing service on or near the SIR components or the SIR wiring, disable the SIR system. Refer to Disabling the SIR System in SIR. CAUTION: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components. CAUTION: Batteries produce explosive gases, contain corrosive acid, and supply levels of electrical current high enough to cause burns. Therefore, to reduce the risk of personal injury when working near a battery: - Always shield your eyes and avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow the battery electrolyte to contact the eyes or the skin. Flush immediately and thoroughly any contacted areas with water and get medical help. - Follow each step of the jump starting procedure in order. - Treat both the booster and the discharged batteries carefully when using the jumper cables. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions > Technician Safety Information > Page 2887 Jump Starting: Vehicle Damage Warnings NOTE: Never operate the starter motor for more than 30 seconds at a time. Allow it to cool for at least two minutes. Overheating, caused by too much cranking, will damage the starter motor. NOTE: Do not use the boost, jump start, crank, or an equivalent setting that may be available on the battery charger for prolonged charging of the battery. Using such settings may damage the battery due to overheating, excessive gassing, or spewing of electrolyte from the vents. NOTE: This vehicle has a 12 Volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 Volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions > Page 2888 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels at electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 Volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 Volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. 1. Position the vehicle with the booster (charged) battery so that the jumper cables will comfortably reach. - Do not let the two vehicles touch. - Make sure that the jumper cables do not have loose clamps, or missing insulation. 2. Place the automatic transmission in PARK. 3. Set the parking brake. 4. Block the wheels. 5. Turn off all electrical loads that are not needed (leave the hazard flashers ON). 6. Turn OFF the ignition switch. 7. Attach the end of one jumper cable to the positive terminal of the booster battery (A1). 8. Open the junction block cover. 9. Attach the other end of the same jumper cable to the junction block terminal (B2). 10. Attach one end of the remaining jumper cable to the negative terminal of the booster battery (A3). NOTE: Do not connect the negative booster cable to the housings of other vehicle electrical accessories or equipment. The current flow during jump starting may damage such equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions > Page 2889 11. Make the final connection of the negative cable to the grounding tab on the generator mounting bracket, connected directly to the block, away from the discharged battery (B4). 12. Start the engine of the vehicle that is providing the jump start and turn off all electrical accessories. 13. Crank the engine of the vehicle with the discharged battery. 14. Reverse the steps exactly when removing the jumper cables. The negative battery cable must first be disconnected from the engine that was jump started. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications The lowest reading should not be less than 70 percent of the highest reading. No cylinder reading should be less than 689 kPa (100 psi). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2895 Compression Check: Testing and Inspection A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the head gasket. Important: Remove the Powertrain Control Module (PCM) and the ignition fuses from the I/P fuse block. 1. Disable the ignition. 2. Disable the fuel systems. 3. Remove the spark plugs from all the cylinders. 4. Remove the air duct from the throttle body. 5. Block the throttle plate in the open position. 6. Measure the engine compression, using the following procedure: 6.1. Firmly install the compression gauge to the spark plug hole. 6.2. Have an assistant crank the engine through at least 4 compression strokes in the testing cylinder. 6.3. Record the readings on the gauge at each stroke. 6.4. Disconnect the gauge. 6.5. Repeat the compression test for each cylinder. 7. Record the compression readings from all of the cylinders. - The lowest reading should not be less than 70 percent of the highest reading. - No cylinder reading should be less than 689 kPa (100 psi). 8. The following list is examples of the possible measurements: - When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each cylinder. - When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal compression, the piston rings may be the cause. - If the compression improves considerably with the addition of three squirts of oil, the piston rings may be the cause. - When the compression is low on the first stroke and does not build up in the following strokes, the valves may be the cause. - The addition of oil does not affect the compression, the valves may be the cause. - When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause. 9. Remove the block from the throttle plate. 10. Install the air duct to the throttle body. 11. Install the spark plugs. 12. Install the Powertrain Control Module (PCM) fuse. 13. Install the ignition fuse to the I/P fuse block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Service and Repair Camshaft Bearing: Service and Repair Refer to Engine Service and Repair for additional engine repair information for this component. See: Service and Repair If an internal engine component does not have a separate service procedure at this location, the manufacturer did not provide one. Please refer to "Unit Repair" under Engine/Service and Repair for available service procedures. See: Service and Repair "Unit Repair" typically covers service procedures, machining, cleaning, inspection, and fitting necessary as part of engine overhaul: - Cylinder Boring and Honing - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Camshaft Bearings - Replacement - Connecting Rod and Piston - Disassembly - Cylinder Head - Disassembly - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Oil Pump - Disassembly - Pistons and Rings - Fitting - Thread repair information - Valve and Seat Grinding (Valve Job) - See also "Cylinder Head Assembly" See: Cylinder Head Assembly - Timing Components (Chain, Belt, Gears) service - See also "Timing Components" See: Timing Components Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Camshaft Sprocket - Design Identification Camshaft Gear/Sprocket: Technical Service Bulletins Camshaft Sprocket - Design Identification File In Section: 06 - Engine/Propulsion System Bulletin No.: 00-06-01-004 Date: March, 2000 INFORMATION Subject: Identification of Camshaft Sprocket Design for Service Models: 2000 Buick Century 2000 Chevrolet Impala, Malibu, Monte Carlo, Venture 2000 Oldsmobile Alero, Silhouette 2000 Pontiac Grand Am, Montana With 3.1 L or 3.4 L Engine (VINs J, E - RPOs LGB, LA1) Some dealers may have parts identification concerns regarding the 2000 3.1 L and 3.4 L engines (RPOs LG8, LA1) camshaft and crankshaft timing components. Dealers may have encountered that parts ordered do not fit, or have a different appearance than those the vehicle was originally equipped with. The cause is revised drive sprockets, chain and dampener introduced into vehicle production, replacing previous design components. This occurred during the model year. Important: Previous and revised design components may not be intermixed with each other. Attempting to use a mix of the two types of timing components will result in the inability to assemble and time the vehicle. Reference the following figures and associated pant numbers to clarify which replacement parts should be ordered, depending upon which design the vehicle was equipped with. If it is necessary to replace all components during service, it is recommended to use the revised design components. Parts are currently available from GMSPO. Previous Design Sprocket Identification And Part Numbers Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Camshaft Sprocket - Design Identification > Page 2904 Revised Sprocket Design Revised Sprocket Identification And Part Numbers Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Page 2905 Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt 103 lb. ft. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Thrust Plate > Component Information > Specifications Camshaft Thrust Plate: Specifications Camshaft Thrust Plate Screw 89 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Lobe Lift (Intake and Exhaust) 0.2727 in Journal Diameter 1.868 - 1.869 in Camshaft Bearing Bore Diameter-Front and Rear 2.009 - 2.011 in Camshaft Bearing Bore Diameter-Middle #2 and #3 1.999 - 2.001 in Camshaft Bearing Inside Diameter 1.871 - 1.872 in Journal Clearance 0.001 - 0.0039 in Journal Runout-Max 0.001 in Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2912 Camshaft: Service and Repair Refer to Engine Service and Repair for additional engine repair information for this component. See: Service and Repair If an internal engine component does not have a separate service procedure at this location, the manufacturer did not provide one. Please refer to "Unit Repair" under Engine/Service and Repair for available service procedures. See: Service and Repair "Unit Repair" typically covers service procedures, machining, cleaning, inspection, and fitting necessary as part of engine overhaul: - Cylinder Boring and Honing - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Camshaft Bearings - Replacement - Connecting Rod and Piston - Disassembly - Cylinder Head - Disassembly - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Oil Pump - Disassembly - Pistons and Rings - Fitting - Thread repair information - Valve and Seat Grinding (Valve Job) - See also "Cylinder Head Assembly" See: Cylinder Head Assembly - Timing Components (Chain, Belt, Gears) service - See also "Timing Components" See: Timing Components Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications Lifter / Lash Adjuster: Specifications Valve Lifter Guide Bolt 89 in.lb Roller Lifter Hydraulic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Replacement Lifter / Lash Adjuster: Service and Repair Valve Lifter Replacement Removal Procedure 1. Remove the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement (Left Front) or Valve Rocker Arm Cover Replacement (Right Pear). 2. Remove the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement (Left Front) or Valve Rocker Arm Cover Replacement (Right Rear). 3. Remove the upper intake manifold. Refer to Intake Manifold Replacement (Upper) or Intake Manifold Replacement (Lower). 4. Remove the lower intake manifold. Refer to Intake Manifold Replacement (Upper) or Intake Manifold Replacement (Lower). 5. Remove the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Replacement. 6. Remove the lifter guide bolts. 7. Remove the lifter guide(s). 8. Remove the valve lifter(s). 9. Clean the gasket surfaces. 10. Clean the valve train parts. 11. Inspect the valve lifters and the cam lobes for wear. Refer to Valve Lifters Clean and Inspect. Installation Procedure 1. Install the valve lifter(s) to the same location from which they were removed. 2. Install the lifter guide(s) and bolts. Refer to Valve Lifter Installation. 3. Install the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Replacement. 4. Install the lower intake manifold. Refer to Intake Manifold Replacement (Upper) or Intake Manifold Replacement (Lower). 5. Install the upper intake manifold. Refer to Intake Manifold Replacement (Upper) or Intake Manifold Replacement (Lower). 6. Install the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement (Left Front) or Valve Rocker Arm Cover Replacement (Right Rear). 7. Install the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement (Left Front) or Valve Rocker Arm Cover Replacement (Right Rear). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Replacement > Page 2918 Lifter / Lash Adjuster: Service and Repair Additional Information Refer to Engine Service and Repair for additional engine repair information for this component. See: Service and Repair If an internal engine component does not have a separate service procedure at this location, the manufacturer did not provide one. Please refer to "Unit Repair" under Engine/Service and Repair for available service procedures. See: Service and Repair "Unit Repair" typically covers service procedures, machining, cleaning, inspection, and fitting necessary as part of engine overhaul: - Cylinder Boring and Honing - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Camshaft Bearings - Replacement - Connecting Rod and Piston - Disassembly - Cylinder Head - Disassembly - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Oil Pump - Disassembly - Pistons and Rings - Fitting - Thread repair information - Valve and Seat Grinding (Valve Job) - See also "Cylinder Head Assembly" See: Cylinder Head Assembly - Timing Components (Chain, Belt, Gears) service - See also "Timing Components" See: Timing Components Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair Push Rod: Service and Repair Valve Rocker Arm and Push Rod Replacement - Tools Required J36660-A Torque Angle Meter Removal Procedure 1. Remove the valve rocker covers. Important: Keep the components separated in order to install the components in the same location. 2. Remove the rocker arm bolts. 3. Remove the rocker arms. Important: Keep the pushrods in order in order to install the pushrods in the original position. 4. Remove the pushrods. Installation Procedure 1. Install the pushrods in the original location. - Coat the ends of the pushrods with GM P/N 1052356 or the equivalent. - The intake pushrods are identified with yellow stripes and are 5 3/4 inches long. - Exhaust pushrods are identified with green stripes and are 6 inches long. Ensure that the pushrods seat in the lifter. 2. Install the rocker arms. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the rocker arm bolts. See TSB 02-06-01-034 Tighten the rocker arm bolts to 14 Nm (124 inch lbs.). Use the J36660-A in order to tighten the bolts an additional 30 degrees. 4. Install the valve rocker covers. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Engine - Rocker Arm Bolt Tightening Specification Update Rocker Arm Assembly: Technical Service Bulletins Engine - Rocker Arm Bolt Tightening Specification Update File In Section: 06 - Engine/propulsion System Bulletin No.: 02-06-01-034 Date: October, 2002 SERVICE MANUAL UPDATE Subject: Revised Rocker Arm Bolt Fastener Tightening Specification Models: 1996-1998 Buick Skylark 1996-2002 Buick Regal 1997-2002 Buick Century 1996 Chevrolet Beretta, Corsica, Lumina APV 1996-2001 Chevrolet Lumina 1996-2002 Chevrolet Monte Carlo 1997 Chevrolet Venture 1997-2003 Chevrolet Malibu 2000-2002 Chevrolet Impala 1996-1997 Oldsmobile Cutlass Supreme, Silhouette 1996-1998 Oldsmobile Achieve 1998-1999 Oldsmobile Cutlass, Intrigue 1999-2002 Oldsmobile Alero 1996-1997 Pontiac Trans Sport 1996-2003 Pontiac Grand Am, Grand Prix with 3.1L or 3.4L Engine (VINs M, J, E - RPOs L82, LG8, LA1) This bulletin is being issued to revise the rocker arm bolt fastener tightening specification found in several procedures in the Engine Mechanical - 3.1L sub-section and the Engine Mechanical - 3.4L sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The correct torque for the rocker arm bolt is 14 N.m (124 lb in) plus 30 degrees. This specification can be found in Fastener Tightening Specifications, Valve Rocker Arm and Push Rod Replacement and Lower Intake Manifold Replacement (for 1996 Chevrolet Beretta/Corsica, 1996-1997 Buick Skylark, Pontiac Grand Am, Oldsmobile Achieva and 1997 Chevrolet Malibu ONLY). DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2926 Rocker Arm Assembly: Specifications This article has been updated with bulletin No: 02-06-01-034. REVISED ROCKER ARM BOLT FASTENER TIGHTENING SPECIFICATION Rocker arm bolt ................................................................................................................................... .................................. 14 N.m (124 lb. in.) plus 30° Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2927 Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement - Tools Required J36660-A Torque Angle Meter Removal Procedure 1. Remove the valve rocker covers. Important: Keep the components separated in order to install the components in the same location. 2. Remove the rocker arm bolts. 3. Remove the rocker arms. Important: Keep the pushrods in order in order to install the pushrods in the original position. 4. Remove the pushrods. Installation Procedure 1. Install the pushrods in the original location. - Coat the ends of the pushrods with GM P/N 1052356 or the equivalent. - The intake pushrods are identified with yellow stripes and are 5 3/4 inches long. - Exhaust pushrods are identified with green stripes and are 6 inches long. Ensure that the pushrods seat in the lifter. 2. Install the rocker arms. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the rocker arm bolts. See TSB 02-06-01-034 Tighten the rocker arm bolts to 14 Nm (124 inch lbs.). Use the J36660-A in order to tighten the bolts an additional 30 degrees. 4. Install the valve rocker covers. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Connecting Rod Bearing Replacement Connecting Rod Bearing: Service and Repair Connecting Rod Bearing Replacement Removal Procedure Notice: Refer to Engine Emission Notice in Service Precautions. Tools Required J 5239 Connecting Rod Bolt Guide Set 1. Remove the oil pan. Refer to Oil Pan Replacement. 2. Remove the oil pump. Refer to Oil Pump Replacement. 3. Remove the crankshaft oil deflector. Refer to Crankshaft Oil Deflector Replacement. 4. Turn the crankshaft until the piston and rod assembly to be serviced is at Bottom Dead Center (BDC). Important: Place matchmarks or numbers on the connecting rod and connecting rod caps. The connecting rod caps must be assembled to their original connecting rod. 5. Remove the connecting rod nuts. 6. Remove the connecting rod cap. 7. Remove the lower connecting rod bearing. Notice: Install thread protector in order to avoid damage to the crankshaft journal. 8. Install the J5239. 9. Push the piston and connecting rod up the cylinder in order to gain access to the upper connecting rod bearing. 10. Remove the upper connecting rod bearing. 11. Wipe oil from the connecting rod bearings and crankshaft connecting rod journal. 12. Inspect the connecting rod bearings. Refer to Piston, Connecting Rod, and Bearings Clean and Inspect. 13. Inspect the connecting rod cap and connecting rod. Refer to Piston, Connecting Rod, and Bearings Clean and Inspect. 14. Inspect the crankshaft connecting rod journal. Refer to Crankshaft and Bearings Clean and Inspect. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Connecting Rod Bearing Replacement > Page 2933 Installation Procedure Notice: Refer to Engine Emission Notice in Service Precautions. Tools Required J 5239 Connecting Rod Bolt Guide Set - J 36660-A Torque Angle Meter 1. Install upper connecting rod bearing into connecting rod. 2. Coat the inside surfaces of the upper connecting rod bearing with new engine oil. 3. Using the J 5239 pull the piston and rod assembly down to the crankshaft. 4. Remove the J 5239. 5. Install the lower connecting rod bearing into the connecting rod cap. 6. Coat the inside surfaces of the lower connecting rod bearing with new engine oil. 7. Install the connecting rod cap with lower connecting rod bearing. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the connecting rod nuts. Refer to Piston, Connecting Rod, and Bearing Installation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Connecting Rod Bearing Replacement > Page 2934 9. Measure the connecting rod side clearance using the following procedure: 9.1. Install all connecting rod bearings. 9.2. Lightly tap each connecting rod parallel to the crankpin in order to make sure the connecting rods have clearance. 9.3. Measure the side clearance between the connecting rod caps using a feeler gage, or dial indicator. Refer to Crankpin (Rod Side Clearance) in Specifications for the connecting rod side clearance. 10. Install the crankshaft oil deflector. Refer to Crankshaft Oil Deflector Replacement. 11. Install the oil pump. Refer to Oil Pump Replacement. 12. Install the oil pan. Refer to Oil Pan Replacement. Piston, Connecting Rod, and Bearing Replacement Removal Procedure - Tools Required J 5239 Connecting Rod Bolt Guide Set - J 24270 Cylinder Bore Ridge Reamer 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the oil pan. Refer to Oil Pan Replacement. 3. Remove the oil pump. Refer to Oil Pump Replacement. 4. Remove the crankshaft oil deflector. Refer to Crankshaft Oil Deflector Replacement. 5. Turn the crankshaft until the piston and rod assembly to be serviced is at Bottom Dead Center (BDC). 6. Lower the engine onto the frame. 7. Lower the vehicle. 8. Remove the engine support fixture. 9. Remove the cylinder head(s). Refer to Cylinder Head Replacement (Left) and/or Cylinder Head Replacement (Right). 10. Use the following procedure in order to remove the ring ridge, as necessary: 10.1. Turn the crankshaft until the piston is at the bottom of its stroke. 10.2. Place a cloth on top of the piston. 10.3. Use the J 24270 in order to remove the piston ring ridge. 10.4. Turn the crankshaft so that the piston is at the top of its stroke. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Connecting Rod Bearing Replacement > Page 2935 10.5. Remove the cloth and cutting debris. 11. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Important: Place matchmarks or numbers on the connecting rod and connecting rod caps. The connecting rod caps must be assembled to their original connecting rod. 12. Remove the connecting rod nuts. 13. Remove the connecting rod cap. 14. Remove the lower connecting rod bearing. Notice: Install thread protector in order to avoid damage to the crankshaft journal. 15. Install the J 5239. 16. Push the piston and rod up through the cylinder. 17. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Connecting Rod Bearing Replacement > Page 2936 18. Remove the connecting rod, upper connecting rod bearing and piston out of the top of the engine block. 19. Wipe oil from the connecting rod bearings and crankshaft connecting rod journal. 20. Inspect the piston. Refer to Piston, Connecting Rod, and Bearings Clean and Inspect. 21. Inspect the connecting rod bearings. Refer to Piston, Connecting Rod, and Bearings Clean and Inspect. 22. Inspect the connecting rod cap and connecting rod. Refer to Piston, Connecting Rod, and Bearings Clean and Inspect. 23. Inspect the crankshaft connecting rod journal. Refer to Crankshaft and Bearings Clean and Inspect. 24. Protect the crankshaft journals from honing debris. 25. Clean the cylinder bores with a light honing. 26. Clean the cylinder bores with hot water and detergent. 27. Swab the bores with a clean, dry cloth. 28. Swab the bores with new engine oil and a clean, dry cloth. Installation Procedure - Tools Required J 5239 Connecting Rod Bolt Guide Set - J 8037 Piston Ring Compressor - J 36660-A Torque Angle Meter 1. Coat the piston, the piston rings, the cylinder bore, and the bearing surfaces with new engine oil. 2. Install the J 5239. 3. Compress the piston rings using the J 8037. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Connecting Rod Bearing Replacement > Page 2937 4. When installing the piston and connecting rod assembly, the stamped arrow on the piston must point to the front of the engine while the flange on the connecting rod must face toward the front of the piston on the left hand, and face toward the rear of the piston on the right hand. 5. Install the piston into its original bore using the J 5239 and the J 8037 and lightly tapping the top of the piston with a wooden hammer handle. 6. Firmly hold the J 8037 against the engine block until all of the piston rings have entered the cylinder bore. 7. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 8. Install the upper connecting rod bearing into the connecting rod. 9. Coat the inside surfaces of the upper connecting rod bearing with new engine oil. 10. Using the J 5239 pull the piston and rod assembly down to the crankshaft. 11. Remove the J 5239. 12. Install the lower connecting rod bearing into the connecting rod cap. 13. Coat the inside surfaces of the lower connecting rod bearing with new engine oil. 14. Install the connecting rod cap. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Connecting Rod Bearing Replacement > Page 2938 - In order to prevent the possibility of rod bolt or bearing cap damage, the bearing caps may need to be tapped into position with a brass or leather mallet before the attaching nuts are installed. Do not use the attaching nuts to pull the bearing caps onto the rod. Failure to observe this information may result in damage to the rod bolt or the bearing cap. 15. Install the connecting rod cap nuts. Refer to Piston, Connecting Rod, and Bearing Installation. 16. Inspect the connecting rod for a binding by prying back and forth with a suitable tool. If necessary, loosen and retighten the connecting rod cap. 17. Measure the connecting rod clearance using the following procedure: 17.1. Install all connecting rod bearings. 17.2. Lightly tap each connecting rod parallel to the crankpin in order to make sure the connecting rods have clearance. 17.3. Measure the side clearance between the connecting rod caps using a feeler gage, or dial indicator. Refer to Crankpin (Rod Side Clearance) in Specifications for the connecting rod side clearance. 18. Lower the vehicle. 19. Install the cylinder head(s). Refer to Cylinder Head Replacement (Left) and/or Cylinder Head Replacement (Right). 20. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 21. Install the crankshaft oil deflector. Refer to Crankshaft Oil Deflector Replacement. 22. Install the oil pump. Refer to Oil Pump Replacement. 23. Install the oil pan. Refer to Oil Pan Replacement. 24. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Connecting Rod Bearing Replacement > Page 2939 Connecting Rod Bearing: Service and Repair Additional Information Refer to Engine Service and Repair for additional engine repair information for this component. See: Service and Repair If an internal engine component does not have a separate service procedure at this location, the manufacturer did not provide one. Please refer to "Unit Repair" under Engine/Service and Repair for available service procedures. See: Service and Repair "Unit Repair" typically covers service procedures, machining, cleaning, inspection, and fitting necessary as part of engine overhaul: - Cylinder Boring and Honing - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Camshaft Bearings - Replacement - Connecting Rod and Piston - Disassembly - Cylinder Head - Disassembly - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Oil Pump - Disassembly - Pistons and Rings - Fitting - Thread repair information - Valve and Seat Grinding (Valve Job) - See also "Cylinder Head Assembly" See: Cylinder Head Assembly - Timing Components (Chain, Belt, Gears) service - See also "Timing Components" See: Timing Components Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Technical Service Bulletins > Engine - New Polymer Coated Piston and Rod Assembly Connecting Rod: Technical Service Bulletins Engine - New Polymer Coated Piston and Rod Assembly File In Section: 06 - Engine/Propulsion System Bulletin No.: 03-06-01-002 Date: February, 2003 INFORMATION Subject: New Polymer Coated Piston and Rod Assembly Models: 2000-2003 Buick Century 2002-2003 Buick Rendezvous 1996 Chevrolet Lumina APV 1997-2003 Chevrolet Venture 1999-2001 Chevrolet Lumina 1999-2003 Chevrolet Malibu, Monte Carlo 2000-2003 Chevrolet Impala 1996-2003 Oldsmobile Silhouette 1999 Oldsmobile Cutlass 1999-2003 Oldsmobile Alero 1996-1999 Pontiac Trans Sport 1999-2003 Pontiac Grand Am 2000-2003 Pontiac Grand Prix, Montana 2001-2003 Pontiac Aztek with 3.1L or 3.4L V-6 Engine (VINs E, J - RPOs LA1, LG8) A new piston and rod assembly has been released for use in the above models. The new piston is Polymer coated and will arrive with the piston rings and connecting rod already assembled to it, but does not contain the connecting rod bearing. Use this new piston assembly any time the need to replace either the piston or connecting rod should arise. The new piston assembly part numbers are shown. Parts are expected to be available from GMSPO February 17, 2003. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Technical Service Bulletins > Page 2944 Connecting Rod: Specifications Connecting Rod Bearing Cap Nut 15 ft.lb + 75 degrees Rod Bearing Journal Clearance 0.0007-0.0024 in Rod Side Clearance 0.007-0.017 in Rod Bearing Bore Diameter 2.124-2.125 in Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Technical Service Bulletins > Page 2945 Connecting Rod: Service and Repair Refer to Engine Service and Repair for additional engine repair information for this component. See: Service and Repair If an internal engine component does not have a separate service procedure at this location, the manufacturer did not provide one. Please refer to "Unit Repair" under Engine/Service and Repair for available service procedures. See: Service and Repair "Unit Repair" typically covers service procedures, machining, cleaning, inspection, and fitting necessary as part of engine overhaul: - Cylinder Boring and Honing - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Camshaft Bearings - Replacement - Connecting Rod and Piston - Disassembly - Cylinder Head - Disassembly - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Oil Pump - Disassembly - Pistons and Rings - Fitting - Thread repair information - Valve and Seat Grinding (Valve Job) - See also "Cylinder Head Assembly" See: Cylinder Head Assembly - Timing Components (Chain, Belt, Gears) service - See also "Timing Components" See: Timing Components Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications Coolant Drain Plug 14 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Coolant Drain Plug, Cylinder Block > Component Information > Specifications > Page 2949 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Balancer Bolt 76 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Main Bearing Cap Torque Crankshaft Main Bearing: Specifications Main Bearing Cap Bolts First Pass 37 lb. ft. Final Pass + 77 Degrees Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Main Bearing Cap Torque > Page 2957 Crankshaft Main Bearing: Specifications Main Bearing Clearance 0.0008-0.0025 in. Crankshaft Main Bearing Inside Bore Diameter 2.6492-2.6502 in. Main Thrust Bearing Clearance 0.0012-0.0030 in. Cylinder Block Main Beraing Bore Diameter 2.8407-2.8412 in. Crankshaft End Play 0.0024 - 0.0083 in Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 2958 Crankshaft Main Bearing: Service and Repair Refer to Engine Service and Repair for additional engine repair information for this component. See: Service and Repair If an internal engine component does not have a separate service procedure at this location, the manufacturer did not provide one. Please refer to "Unit Repair" under Engine/Service and Repair for available service procedures. See: Service and Repair "Unit Repair" typically covers service procedures, machining, cleaning, inspection, and fitting necessary as part of engine overhaul: - Cylinder Boring and Honing - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Camshaft Bearings - Replacement - Connecting Rod and Piston - Disassembly - Cylinder Head - Disassembly - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Oil Pump - Disassembly - Pistons and Rings - Fitting - Thread repair information - Valve and Seat Grinding (Valve Job) - See also "Cylinder Head Assembly" See: Cylinder Head Assembly - Timing Components (Chain, Belt, Gears) service - See also "Timing Components" See: Timing Components Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Main Journal Diameter 2.6473 - 2.6483 in Main Journal Taper 0.0002 in Out Of Round - Max 0.0002 in Flange Runout-Max 0.0016 Crankshaft End Play 0.0024 - 0.0083 in Crankshaft Flange Runout-Max 0.0016 inch Rod Bearing Journal Diameter 1.9987 - 1.9994 in Rod Bearing Journal Taper - Max 0.0002 in Rod Bearing Journal Out Of Round - Max 0.0002 in Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft Oil Deflector Replacement Crankshaft: Service and Repair Crankshaft Oil Deflector Replacement Removal Procedure 1. Remove the oil pan. Refer to Oil Pan Replacement. 2. Remove the oil pump Refer to Oil Pump Replacement. 3. Remove the crankshaft oil deflector nuts. 4. Remove the crankshaft oil deflector. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the crankshaft oil deflector. Install the crankshaft oil deflector nuts. Refer to Oil Pump Installation. 2. Install the oil pump drive and the oil pump. Refer to Oil Pump Installation. 3. Install the oil pan. Refer to Oil Pan Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft Oil Deflector Replacement > Page 2964 Crankshaft: Service and Repair Additional Information Refer to Engine Service and Repair for additional engine repair information for this component. See: Service and Repair If an internal engine component does not have a separate service procedure at this location, the manufacturer did not provide one. Please refer to "Unit Repair" under Engine/Service and Repair for available service procedures. See: Service and Repair "Unit Repair" typically covers service procedures, machining, cleaning, inspection, and fitting necessary as part of engine overhaul: - Cylinder Boring and Honing - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Camshaft Bearings - Replacement - Connecting Rod and Piston - Disassembly - Cylinder Head - Disassembly - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Oil Pump - Disassembly - Pistons and Rings - Fitting - Thread repair information - Valve and Seat Grinding (Valve Job) - See also "Cylinder Head Assembly" See: Cylinder Head Assembly - Timing Components (Chain, Belt, Gears) service - See also "Timing Components" See: Timing Components Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Cord Replacement Engine Block Heater: Service and Repair Coolant Heater Cord Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the engine block heater cord from the engine block heater. 3. Remove the engine block heater cord straps. 4. Disconnect the upper engine block heater cord from the diagonal brace strap. 5. Remove the engine block heater cord. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Cord Replacement > Page 2969 1. Install the engine block heater cord. 2. Connect the engine block heater cord to the diagonal brace strap. 3. Install the new engine block heater cord straps. 4. Connect the engine block heater cord to the engine block heater. 5. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Cord Replacement > Page 2970 Engine Block Heater: Service and Repair Coolant Heater Replacement Removal Procedure 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Disconnect the engine block heater cord from the engine block heater. 4. Loosen the engine block heater screw. 5. Remove the engine block heater. 6. Clean the engine block heater opening. Installation Procedure 1. Coat the following components with the lubricant GM P/N 12345996 or the equivalent: - The engine block heater seal - The cleaned surface of the engine block heater hole 2. Position the heating element at the 3 O'clock position (2). 3. Install the engine block heater. Notice: Refer to Fastener Notice in Service Precautions. 4. Tighten the engine block heater screw. Tighten the engine block heater screw to 2 Nm (18 inch lbs.). 5. Connect the engine block heater cord to the engine block heater. 6. Lower the vehicle. 7. Fill the cooling system. Refer to Draining and Filling Cooling System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Balancer <--> [Harmonic Balancer - Crankshaft Pulley] > Component Information > Specifications Crankshaft Balancer: Specifications Crankshaft Balancer Bolt 76 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Balancer <--> [Harmonic Balancer - Crankshaft Pulley] > Component Information > Specifications > Page 2974 Crankshaft Balancer: Service and Repair Removal Procedure - Tools Required J 24420-C Crankshaft Balancer Remover - J 37096 Flywheel Holder Notice: The inertial weight section of the crankshaft balancer is assembled to the hub with a rubber type material. The correct installation procedures (with the proper tool) must be followed or movement of the inertial weight section of the hub will destroy the tuning of the crankshaft balancer. 1. Remove the drive belt. Refer to Drive Belt Replacement. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Remove the right front tire and wheel. Refer to Tire and Wheel Removal and Installation in Steering and Suspension. 4. Remove the right engine splash shield. Refer to Splash Shield Replacement - Engine (Right) or Splash Shield Replacement - Engine (Left) in Body and Frame. 5. Suitably support the frame. Loosen the right side frame bolts. Lower the right frame for access to the crankshaft balancer bolt with the J 24420-C. Refer to Frame Removal in Body and Frame. 6. Use the J 37096 to hold the flywheel. 7. Remove the crankshaft balancer bolt and the washer. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Balancer <--> [Harmonic Balancer - Crankshaft Pulley] > Component Information > Specifications > Page 2975 8. Remove the crankshaft balancer. Use the J 24420-C. 9. Clean and inspect the crankshaft balancer. Refer to Crankshaft Balancer Clean and Inspect. Installation Procedure - Tools Required J 29113 Crankshaft Balancer Installer 1. Install the crankshaft balancer. Refer to Crankshaft Balancer Installation. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the crankshaft balancer washer and the bolt. Refer to Crankshaft Balancer Installation. 3. Install the right engine splash shield. Refer to Splash Shield Replacement - Engine (Right) or Splash Shield Replacement - Engine (Left) in Body and Frame. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Balancer <--> [Harmonic Balancer - Crankshaft Pulley] > Component Information > Specifications > Page 2976 4. Install the right front tire and wheel. Refer to Tire and Wheel Removal and Installation in Steering and Suspension. 5. Lower the vehicle. 6. Install the drive belt. Refer to Drive Belt Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Technical Service Bulletins > Engine - New Polymer Coated Piston and Rod Assembly Piston: Technical Service Bulletins Engine - New Polymer Coated Piston and Rod Assembly File In Section: 06 - Engine/Propulsion System Bulletin No.: 03-06-01-002 Date: February, 2003 INFORMATION Subject: New Polymer Coated Piston and Rod Assembly Models: 2000-2003 Buick Century 2002-2003 Buick Rendezvous 1996 Chevrolet Lumina APV 1997-2003 Chevrolet Venture 1999-2001 Chevrolet Lumina 1999-2003 Chevrolet Malibu, Monte Carlo 2000-2003 Chevrolet Impala 1996-2003 Oldsmobile Silhouette 1999 Oldsmobile Cutlass 1999-2003 Oldsmobile Alero 1996-1999 Pontiac Trans Sport 1999-2003 Pontiac Grand Am 2000-2003 Pontiac Grand Prix, Montana 2001-2003 Pontiac Aztek with 3.1L or 3.4L V-6 Engine (VINs E, J - RPOs LA1, LG8) A new piston and rod assembly has been released for use in the above models. The new piston is Polymer coated and will arrive with the piston rings and connecting rod already assembled to it, but does not contain the connecting rod bearing. Use this new piston assembly any time the need to replace either the piston or connecting rod should arise. The new piston assembly part numbers are shown. Parts are expected to be available from GMSPO February 17, 2003. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Technical Service Bulletins > Page 2981 Piston: Specifications Diameter-Gaged On The Skirt 13 mm (0.51 inch) Below The Centerline Of The Piston Pin Bore 3.6209 - 3.6216 in Clearance 0.0013 - 0.0027 in Pin Bore 0.9057 - 0.9060 in Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Technical Service Bulletins > Page 2982 Piston: Service and Repair Refer to Engine Service and Repair for additional engine repair information for this component. See: Service and Repair If an internal engine component does not have a separate service procedure at this location, the manufacturer did not provide one. Please refer to "Unit Repair" under Engine/Service and Repair for available service procedures. See: Service and Repair "Unit Repair" typically covers service procedures, machining, cleaning, inspection, and fitting necessary as part of engine overhaul: - Cylinder Boring and Honing - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Camshaft Bearings - Replacement - Connecting Rod and Piston - Disassembly - Cylinder Head - Disassembly - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Oil Pump - Disassembly - Pistons and Rings - Fitting - Thread repair information - Valve and Seat Grinding (Valve Job) - See also "Cylinder Head Assembly" See: Cylinder Head Assembly - Timing Components (Chain, Belt, Gears) service - See also "Timing Components" See: Timing Components Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin <--> [Piston Pin, Engine] > Component Information > Technical Service Bulletins > Engine - New Polymer Coated Piston and Rod Assembly Piston Pin: Technical Service Bulletins Engine - New Polymer Coated Piston and Rod Assembly File In Section: 06 - Engine/Propulsion System Bulletin No.: 03-06-01-002 Date: February, 2003 INFORMATION Subject: New Polymer Coated Piston and Rod Assembly Models: 2000-2003 Buick Century 2002-2003 Buick Rendezvous 1996 Chevrolet Lumina APV 1997-2003 Chevrolet Venture 1999-2001 Chevrolet Lumina 1999-2003 Chevrolet Malibu, Monte Carlo 2000-2003 Chevrolet Impala 1996-2003 Oldsmobile Silhouette 1999 Oldsmobile Cutlass 1999-2003 Oldsmobile Alero 1996-1999 Pontiac Trans Sport 1999-2003 Pontiac Grand Am 2000-2003 Pontiac Grand Prix, Montana 2001-2003 Pontiac Aztek with 3.1L or 3.4L V-6 Engine (VINs E, J - RPOs LA1, LG8) A new piston and rod assembly has been released for use in the above models. The new piston is Polymer coated and will arrive with the piston rings and connecting rod already assembled to it, but does not contain the connecting rod bearing. Use this new piston assembly any time the need to replace either the piston or connecting rod should arise. The new piston assembly part numbers are shown. Parts are expected to be available from GMSPO February 17, 2003. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin <--> [Piston Pin, Engine] > Component Information > Technical Service Bulletins > Page 2987 Piston Pin: Specifications Diameter 0.9052 - 0.9054 in Clearance In Piston 0.0004 - 0.0008 in Fit In Rod 0.0006 - 0.0018 inch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin <--> [Piston Pin, Engine] > Component Information > Technical Service Bulletins > Page 2988 Piston Pin: Service and Repair Refer to Engine Service and Repair for additional engine repair information for this component. See: Service and Repair If an internal engine component does not have a separate service procedure at this location, the manufacturer did not provide one. Please refer to "Unit Repair" under Engine/Service and Repair for available service procedures. See: Service and Repair "Unit Repair" typically covers service procedures, machining, cleaning, inspection, and fitting necessary as part of engine overhaul: - Cylinder Boring and Honing - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Camshaft Bearings - Replacement - Connecting Rod and Piston - Disassembly - Cylinder Head - Disassembly - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Oil Pump - Disassembly - Pistons and Rings - Fitting - Thread repair information - Valve and Seat Grinding (Valve Job) - See also "Cylinder Head Assembly" See: Cylinder Head Assembly - Timing Components (Chain, Belt, Gears) service - See also "Timing Components" See: Timing Components Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Technical Service Bulletins > Engine - New Polymer Coated Piston and Rod Assembly Piston Ring: Technical Service Bulletins Engine - New Polymer Coated Piston and Rod Assembly File In Section: 06 - Engine/Propulsion System Bulletin No.: 03-06-01-002 Date: February, 2003 INFORMATION Subject: New Polymer Coated Piston and Rod Assembly Models: 2000-2003 Buick Century 2002-2003 Buick Rendezvous 1996 Chevrolet Lumina APV 1997-2003 Chevrolet Venture 1999-2001 Chevrolet Lumina 1999-2003 Chevrolet Malibu, Monte Carlo 2000-2003 Chevrolet Impala 1996-2003 Oldsmobile Silhouette 1999 Oldsmobile Cutlass 1999-2003 Oldsmobile Alero 1996-1999 Pontiac Trans Sport 1999-2003 Pontiac Grand Am 2000-2003 Pontiac Grand Prix, Montana 2001-2003 Pontiac Aztek with 3.1L or 3.4L V-6 Engine (VINs E, J - RPOs LA1, LG8) A new piston and rod assembly has been released for use in the above models. The new piston is Polymer coated and will arrive with the piston rings and connecting rod already assembled to it, but does not contain the connecting rod bearing. Use this new piston assembly any time the need to replace either the piston or connecting rod should arise. The new piston assembly part numbers are shown. Parts are expected to be available from GMSPO February 17, 2003. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Technical Service Bulletins > Page 2993 Piston Ring: Specifications Top Groove Side Clearance 0.002 - 0.0033 in Second Groove Side Clearance 0.002 - 0.0035 in Top Ring Gap 0.006 - 0.014 in Second Ring Gap 0.0197 - 0.0280 in Groove Clearance 0.008 in Gap with segment at 92.0 mm (3.62 inch) 0.0098 - 0.05 in Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Technical Service Bulletins > Page 2994 Piston Ring: Service and Repair Refer to Engine Service and Repair for additional engine repair information for this component. See: Service and Repair If an internal engine component does not have a separate service procedure at this location, the manufacturer did not provide one. Please refer to "Unit Repair" under Engine/Service and Repair for available service procedures. See: Service and Repair "Unit Repair" typically covers service procedures, machining, cleaning, inspection, and fitting necessary as part of engine overhaul: - Cylinder Boring and Honing - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Camshaft Bearings - Replacement - Connecting Rod and Piston - Disassembly - Cylinder Head - Disassembly - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Oil Pump - Disassembly - Pistons and Rings - Fitting - Thread repair information - Valve and Seat Grinding (Valve Job) - See also "Cylinder Head Assembly" See: Cylinder Head Assembly - Timing Components (Chain, Belt, Gears) service - See also "Timing Components" See: Timing Components Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair RELIEF PROCEDURE Tools Required ^ J34730-1A Fuel Pressure Gauge ^ J34730-262 Fuel Pressure Gauge Fitting CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery terminal. IMPORTANT: Mount the fuel pressure gauge fitting below the belt to avoid contact with the belt. 2. Install the J 34730-262 fuel pressure gauge fitting adaptor to the fuel pressure connection. 3. Connect fuel pressure gauge J 34730-1A to the fuel gauge pressure fitting. Wrap a shop towel around the fuel pressure connection while connecting the fuel pressure gauge in order to avoid spillage. 4. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the fuel pressure gauge into an approved container. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Cylinder Head Bolts > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Head Bolt Torque/Sequence Cylinder Head Bolts: Technical Service Bulletins Engine - Revised Cylinder Head Bolt Torque/Sequence INFORMATION Bulletin No.: 02-06-01-003B Date: April 15, 2008 Subject: Revised Cylinder Head Bolt Torque Specification and Tightening Sequence Models: 1994-1998 Buick Skylark 1994-2002 Buick Century, Regal 2002 Buick Rendezvous 1994-1996 Chevrolet Beretta, Corsica, Lumina APV 1994-2000 Chevrolet Camaro, Lumina 1994-2002 Chevrolet Monte Carlo 1997-2002 Chevrolet Malibu, Venture 2000-2002 Chevrolet Impala 1993-1996 Oldsmobile Ciera 1993-1997 Oldsmobile Cutlass Supreme 1994-2002 Oldsmobile Silhouette 1996-1999 Oldsmobile Cutlass 1998 Oldsmobile Achieva 1999-2002 Oldsmobile Alero 1994-2000 Pontiac Firebird, TransSport 1994-2002 Pontiac Grand Am, Grand Prix 1999-2002 Pontiac Montana 2001-2002 Pontiac Aztek with 3.1L or 3.4L Engine (VINs J, E - RPOs LG8, LA) Supercede: This bulletin is being revised to include a Notice advising that the cylinder head bolts are NOT to be re-used. Please discard Corporate Bulletin Number 02-06-01-003A (Section 06 - Engine). Notice: This component uses torque-to-yield bolts. When servicing this component do not re-use the bolts. New torque-to-yield bolts must be installed. Re-using used torque-to-yield bolts will not provide proper bolt torque and clamp load. Failure to install NEW torque-to-yield bolts may lead to engine damage. The cylinder head bolt torque and tightening sequence have been revised. This revision has been made in the SI. If you are using a paper version of this Service Manual please make a reference to this bulletin on the affected page. The revised specification is as follows: Tighten the NEW cylinder head bolts to 60 N.m (44 lb ft) in the order shown. Use the J 36660-A torque angle meter in order to rotate the cylinder head bolts an additional 95 degrees. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Cylinder Head Bolts > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Head Bolt Torque/Sequence > Page 3006 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Engine - Rocker Arm Bolt Tightening Specification Update Rocker Arm Assembly: Technical Service Bulletins Engine - Rocker Arm Bolt Tightening Specification Update File In Section: 06 - Engine/propulsion System Bulletin No.: 02-06-01-034 Date: October, 2002 SERVICE MANUAL UPDATE Subject: Revised Rocker Arm Bolt Fastener Tightening Specification Models: 1996-1998 Buick Skylark 1996-2002 Buick Regal 1997-2002 Buick Century 1996 Chevrolet Beretta, Corsica, Lumina APV 1996-2001 Chevrolet Lumina 1996-2002 Chevrolet Monte Carlo 1997 Chevrolet Venture 1997-2003 Chevrolet Malibu 2000-2002 Chevrolet Impala 1996-1997 Oldsmobile Cutlass Supreme, Silhouette 1996-1998 Oldsmobile Achieve 1998-1999 Oldsmobile Cutlass, Intrigue 1999-2002 Oldsmobile Alero 1996-1997 Pontiac Trans Sport 1996-2003 Pontiac Grand Am, Grand Prix with 3.1L or 3.4L Engine (VINs M, J, E - RPOs L82, LG8, LA1) This bulletin is being issued to revise the rocker arm bolt fastener tightening specification found in several procedures in the Engine Mechanical - 3.1L sub-section and the Engine Mechanical - 3.4L sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The correct torque for the rocker arm bolt is 14 N.m (124 lb in) plus 30 degrees. This specification can be found in Fastener Tightening Specifications, Valve Rocker Arm and Push Rod Replacement and Lower Intake Manifold Replacement (for 1996 Chevrolet Beretta/Corsica, 1996-1997 Buick Skylark, Pontiac Grand Am, Oldsmobile Achieva and 1997 Chevrolet Malibu ONLY). DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 3011 Rocker Arm Assembly: Specifications This article has been updated with bulletin No: 02-06-01-034. REVISED ROCKER ARM BOLT FASTENER TIGHTENING SPECIFICATION Rocker arm bolt ................................................................................................................................... .................................. 14 N.m (124 lb. in.) plus 30° Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 3012 Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement - Tools Required J36660-A Torque Angle Meter Removal Procedure 1. Remove the valve rocker covers. Important: Keep the components separated in order to install the components in the same location. 2. Remove the rocker arm bolts. 3. Remove the rocker arms. Important: Keep the pushrods in order in order to install the pushrods in the original position. 4. Remove the pushrods. Installation Procedure 1. Install the pushrods in the original location. - Coat the ends of the pushrods with GM P/N 1052356 or the equivalent. - The intake pushrods are identified with yellow stripes and are 5 3/4 inches long. - Exhaust pushrods are identified with green stripes and are 6 inches long. Ensure that the pushrods seat in the lifter. 2. Install the rocker arms. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the rocker arm bolts. See TSB 02-06-01-034 Tighten the rocker arm bolts to 14 Nm (124 inch lbs.). Use the J36660-A in order to tighten the bolts an additional 30 degrees. 4. Install the valve rocker covers. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left Front) Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement (Left Front) Removal Procedure 1. Drain the engine coolant. Refer to Draining and Filling Cooling System. 2. Disconnect the left spark plug wires. Refer to Spark Plug Wire Harness Replacement in Powertrain Management. 3. Remove the right engine mount strut at the engine. Refer to Engine Mount Strut Replacement (Left) or Engine Mount Strut Replacement (Right). 4. Remove the AIR check valve/pipe if equipped. Refer to AIR Check Valve/Pipe Replacement -Bank 1 in Computers and Controls. 5. Remove the thermostat bypass hose and pipe. Refer to Thermostat Bypass Pipes Replacement in Cooling System. 6. Remove the positive crankcase ventilation (PCV) valve from the left valve rocker arm cover. 7. Remove the left valve rocker arm cover bolts. 8. Remove the left valve rocker arm cover. 9. Remove the left valve rocker arm cover gasket. 10. Clean the valve rocker arm cover. Refer to Valve Rocker Arm Cover Clean and Inspect. 11. Clean the valve rocker arm cover gasket sealing surfaces on the cylinder head and the lower intake manifold. Installation Procedure 1. Install a new left valve rocker arm cover gasket into the valve rocker arm cover. Important: Apply sealant GM P/N 12345739 or equivalent at the cylinder head to lower intake manifold joint. 2. Apply sealant at the cylinder head to lower intake manifold joint at the rear of the lower intake manifold (1). Important: Apply sealant GM P/N 12345739 or equivalent at the cylinder head to lower intake manifold joint. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left Front) > Page 3017 3. Apply sealant at the cylinder head to lower intake manifold joint at the front of the lower intake manifold (1). 4. Install the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Installation (Left Side). 5. Install the positive crankcase ventilation (PCV) valve to the left valve rocker arm cover. 6. Install the thermostat bypass hose and pipe. Refer to Thermostat Bypass Pipes Replacement in Cooling System. 7. Install the AIR check valve/pipe if equipped. Refer to AIR Check Valve/Pipe Replacement - Bank 1 in Computers and Controls. 8. Install the right engine mount strut at the engine. Refer to Engine Mount Strut Replacement (Left) or Engine Mount Strut Replacement (Right). 9. Connect the left spark plug wires. Refer to Spark Plug Wire Harness Replacement in Powertrain Management. 10. Fill the engine cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left Front) > Page 3018 Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement (Right Rear) Removal Procedure 1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 2. Remove the drive belt. Refer to Drive Belt Replacement. 3. Remove the generator. Refer to Generator Replacement in Starting and Charging. 4. Remove the generator bracket. Refer to Generator Bracket Replacement in Starting and Charging. 5. Disconnect the right spark plug wires. Refer to Spark Plug Wire Harness Replacement in Powertrain Management. 6. Disconnect the vacuum hoses from the evaporative emission canister purge solenoid valve. 7. Remove the evaporative emission canister purge solenoid valve and the AIR check valve/pipe if equipped. Refer to AIR Check Valve/Pipe Replacement - Bank 2 in Computers and Controls. 8. Remove the ignition coil bracket with the coils. Refer to Ignition Control Module Replacement in Computers and Controls. 9. Remove the vacuum hose from the grommet in the right valve rocker arm cover. 10. Remove the right valve rocker arm cover bolts. 11. Remove the right valve rocker arm cover. 12. Remove the right valve rocker arm cover gasket. 13. Clean the valve rocker arm cover. Refer to Valve Rocker Arm Cover Clean and Inspect. 14. Clean the valve rocker arm cover gasket sealing surfaces on the cylinder head and the lower intake manifold. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left Front) > Page 3019 1. Install a new right valve rocker arm cover gasket to the valve rocker arm cover. Important: Apply sealant GM P/N 12345739 or equivalent at the cylinder head to lower intake manifold joint. 2. Apply sealant at the cylinder head to lower intake manifold joint at the rear of the lower intake manifold (1). Important: Apply sealant GM P/N 12345739 or equivalent at the cylinder head to lower intake manifold joint. 3. Apply sealant at the cylinder head to lower intake manifold joint at the front of the lower intake manifold (1). 4. Install the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Installation (Right Side). 5. Install the vacuum hose to the grommet in the right valve rocker arm cover. 6. Install the ignition coil bracket with coils. Refer to Ignition Control Module Replacement in Computers and Controls. 7. Install the AIR check valve/pipe (if equipped) and the evaporative emission canister purge solenoid valve. Refer to AIR Check Valve/Pipe Replacement - Bank 1 in Computers and Controls. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left Front) > Page 3020 8. Connect the vacuum hoses from the evaporative emission canister purge solenoid valve. 9. Connect the right spark plug wires. Refer to Spark Plug Wire Harness Replacement in Powertrain Management. 10. Install the generator bracket. Refer to Generator Bracket Replacement in Starting and Charging. 11. Install the generator. Refer to Generator Replacement in Starting and Charging. 12. Install the drive belt. Refer to Drive Belt Replacement. 13. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Service and Repair Valve Guide: Service and Repair Refer to Engine Service and Repair for additional engine repair information for this component. See: Service and Repair If an internal engine component does not have a separate service procedure at this location, the manufacturer did not provide one. Please refer to "Unit Repair" under Engine/Service and Repair for available service procedures. See: Service and Repair "Unit Repair" typically covers service procedures, machining, cleaning, inspection, and fitting necessary as part of engine overhaul: - Cylinder Boring and Honing - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Camshaft Bearings - Replacement - Connecting Rod and Piston - Disassembly - Cylinder Head - Disassembly - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Oil Pump - Disassembly - Pistons and Rings - Fitting - Thread repair information - Valve and Seat Grinding (Valve Job) - See also "Cylinder Head Assembly" See: - Timing Components (Chain, Belt, Gears) service - See also "Timing Components" See: Timing Components Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Seat Angle 45 deg Seat Width-Intake 0.061 - 0.071 in Seat Width-Exhaust 0.067 - 0.079 in Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Valve Spring Valve Springs Free Length 1.89 in Valve Springs Load (Closed) 75 lbf @ 1.701 in Valve Springs Load (Open) 230 lbf @ 1.260 inch Installed Height Intake-Exhaust 1.701 in Approx. # or coils 6.55 in Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Additional Information Valve Spring: Service and Repair Additional Information Refer to Engine Service and Repair for additional engine repair information for this component. See: Service and Repair If an internal engine component does not have a separate service procedure at this location, the manufacturer did not provide one. Please refer to "Unit Repair" under Engine/Service and Repair for available service procedures. See: Service and Repair "Unit Repair" typically covers service procedures, machining, cleaning, inspection, and fitting necessary as part of engine overhaul: - Cylinder Boring and Honing - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Camshaft Bearings - Replacement - Connecting Rod and Piston - Disassembly - Cylinder Head - Disassembly - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Oil Pump - Disassembly - Pistons and Rings - Fitting - Thread repair information - Valve and Seat Grinding (Valve Job) - See also "Cylinder Head Assembly" See: - Timing Components (Chain, Belt, Gears) service - See also "Timing Components" See: Timing Components Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Additional Information > Page 3032 Valve Spring: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement For further information this component and the system that it is a part of, please refer to Engine, Push Rod, in Service and Repair. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Valve Face Angle 45 deg Valve Seat Runout 0.001 in Valve Margin - Minimum Intake 0.083 in Valve Margin - Minimum Exhaust 0.106 in Valve Stem Clearance 0.0010 - 0.0027 in Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 3036 Valve: Service and Repair Refer to Engine Service and Repair for additional engine repair information for this component. See: Service and Repair If an internal engine component does not have a separate service procedure at this location, the manufacturer did not provide one. Please refer to "Unit Repair" under Engine/Service and Repair for available service procedures. See: Service and Repair "Unit Repair" typically covers service procedures, machining, cleaning, inspection, and fitting necessary as part of engine overhaul: - Cylinder Boring and Honing - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Camshaft Bearings - Replacement - Connecting Rod and Piston - Disassembly - Cylinder Head - Disassembly - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Oil Pump - Disassembly - Pistons and Rings - Fitting - Thread repair information - Valve and Seat Grinding (Valve Job) - See also "Cylinder Head Assembly" See: - Timing Components (Chain, Belt, Gears) service - See also "Timing Components" See: Timing Components Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 3042 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 3043 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 3044 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 3045 Drive Belt: Specifications Drive Belt Shield Bolt 89 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 3046 Drive Belt: Diagrams Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Notice: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3049 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3050 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3051 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3052 Drive Belt: Testing and Inspection Drive Belt Chirping Notice: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3053 Drive Belt Squeal Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3054 Notice: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 3055 Drive Belt: Service and Repair Removal Procedure Important: After the new drive belt is installed, make sure that the mark on the drive belt tensioner is in range, as indicated on the tensioner housing. 1. Rotate the drive belt tensioner in order to release the pressure on the drive belt. 2. Remove the drive belt. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 3056 1. Install the drive belt to all of the pulleys except the generator pulley. 2. Rotate the drive belt tensioner in order to install the drive belt over the generator pulley. 3. Make sure that the drive belt is properly routed. Important: Make sure the mark on the drive belt tensioner is in range, as indicated on the tensioner housing. 4. Make sure the drive belt tensioner is operating properly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Drive Belt Tensioner Bolt 37 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 3060 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 3061 Drive Belt Tensioner: Service and Repair Removal Procedure 1. Reposition the coolant recovery reservoir for access. Refer to Coolant Recovery Reservoir Replacement. 2. Remove the drive belt. Refer to Drive Belt Replacement. 3. Remove the drive belt tensioner bolt. 4. Remove the drive belt tensioner. Installation Procedure 1. Install the drive belt tensioner. Refer to Drive Belt Tensioner Installation. 2. Install the drive belt. Refer to Drive Belt Replacement. 3. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Service and Repair Engine Accessory Bracket: Service and Repair Removal Procedure - Tools Required J 28467-360 Universal Engine Support Fixture - J 28467-90A Engine Support Adapters - J 36462-A Engine Support Adapter Leg Set 1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 2. Carefully disconnect the throttle body air inlet duct. 3. Remove the engine mount struts. Refer to Engine Mount Strut Replacement (Left) and Engine Mount Strut Replacement (Right). 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the three-way catalytic converter pipe from the right exhaust manifold. Refer to Catalytic Converter Replacement in Powertrain Management. 6. Remove the right front wheel and tire. Refer to Tire and Wheel Removal and Installation in Steering and Suspension. 7. Remove the right engine splash shield. Refer to Splash Shield Replacement - Engine (Right) or Splash Shield Replacement - Engine (Left) in Body and Frame. 8. Remove the engine mount lower nuts. 9. Lower the vehicle. 10. Use the J 28467-360 in order to raise the engine. 11. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 12. Remove the engine mount bracket-to-oil pan bolts. 13. Remove the engine mount and the engine mount bracket. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Service and Repair > Page 3065 14. Remove the engine mount upper nuts. 15. Remove the engine mount from the engine mount bracket. Installation Procedure 1. Install the engine mount to the engine mount bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine mount upper nuts. Tighten the engine mount upper nuts to 47 Nm (35 ft. lbs.). 3. Install the engine mount bracket with the engine mount to the oil pan. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Service and Repair > Page 3066 4. Install the engine mount bracket-to-oil pan bolts. Tighten the engine mount bracket bolts to 58 Nm (43 ft. lbs.). 5. Lower the vehicle. 6. Lower the engine. 7. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 8. Install the engine mount lower nuts. Tighten the engine mount lower nuts to 43 Nm (32 ft. lbs.). 9. Install the right engine splash shield. Refer to Splash Shield Replacement - Engine (Right) or Splash Shield Replacement - Engine (Left) in Body and Frame. 10. Install the right front wheel and tire. Refer to Tire and Wheel Removal and Installation in Steering and Suspension. 11. Connect the three-way catalytic converter pipe to the right exhaust manifold. Refer to Catalytic Converter Replacement in Powertrain Management. 12. Lower the vehicle. 13. Remove the J28467-360. 14. Install the engine mount struts. Refer to Engine Mount Strut Replacement (Left) and Engine Mount Strut Replacement (Right). 15. Carefully connect the throttle body air inlet duct. 16. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 02-03-08-002 > Feb > 02 > Suspension - Front of Vehicle Too Low or Bottoms Out Engine Mount: Customer Interest Suspension - Front of Vehicle Too Low or Bottoms Out File in Section: 03 - Suspension Bulletin No.: 02-03-08-002 Date: February, 2002 TECHNICAL Subject: Front of Vehicle Sits Too Low, Bottoms Out Over Bumps (Replace Front Coil Springs, Inspect/Replace Frame and Mount) Models: 2000-2001 Chevrolet Impala with RPO 9C1 Police Car and 9C3 SEO Vehicle Police Car, Limited Content Built Prior to VIN Breakpoint 29140498 Condition Some customers may comment that the front of the vehicle sits too low and bottoms out over bumps. Cause This condition may be caused by the additional weight of the Police Package added to the vehicle. Correction Follow the service procedure below. Measuring J and K Trim Heights 1. Place the vehicle on a level surface such as an alignment rack. 2. Set the tire pressures on all Police vehicles. Tire Inflation Pressure Specifications Set the tire inflation pressure for Police Vehicles at 240 kPa (35 psi). 3. Verify the fuel level. Add additional weight if necessary to simulate a full tank. 4. Remove any additional items from the vehicle's interior. 5. Empty the rear compartment except for the spare tire. 6. Close the deck lid. 7. Close the doors 8. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 02-03-08-002 > Feb > 02 > Suspension - Front of Vehicle Too Low or Bottoms Out > Page 3075 Important: ^ Lift the front bumper at the center 38 mm (1.05 in) and gently release allowing the vehicle to settle. Push the bumper down 38 mm (1.05 in) and gently release allowing the vehicle to rise. Repeat this procedure for the rear bumper. ^ All dimensions are measured vertical to the ground. 9. Measure the J and K heights 230 mm-250 mm (9.06 in-9.84 in). If the J and K heights are below the specifications listed above, replace the front strut coil springs, P/N 22133025. Refer to Strut, Strut Component and/or Spring Replacement in the Service Manual (SI2000 Document ID # 652878). Frame Inspection/Replacement 1. Raise the vehicle. Important: ^ Vehicles with damage to the front frame rail due to impacts with an object are not covered under warranty. ^ Scrapes on the front frame rail will be covered under warranty. 2. Inspect the frame along the front edge for damage due to the vehicle bottoming out. 3. Inspect the frame for bending using a straight edge along the right side of the frame rail below the engine mount. 4. Remove the frame if the frame is damaged or bent. Refer to Frame Replacement in Body and Accessories in the Service Manual (SI2000 Document ID # 728902). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 02-03-08-002 > Feb > 02 > Suspension - Front of Vehicle Too Low or Bottoms Out > Page 3076 5. Remove the bolts retaining the engine mount bracket to the engine. 6. Remove the engine mount from the bracket. 7. Replace the engine mount bracket with P/N 10321856. 8. Install the engine mount to the bracket. Tighten Tighten the engine mount upper nuts to 78 N.m (58 lb ft). 9. Install the engine mount bracket with the engine mount to the engine. Tighten Tighten the engine mount bracket bolts to 102 Nm (75 lb ft). Important: ^ Replace the frame mounting bolts, P/N 10403403. ^ Only replace the frame insulators if necessary, front upper P/N 10402880, front lower P/N 10402882, rear upper P/N 10402881, and rear lower P/N 10299475. 10. Replace the frame, P/N 10322679. Refer to Frame Replacement in Body and Accessories in the Service Manual (SI2000 Document ID # 793554). 11. Align the vehicle. Refer to Wheel Alignment in the Service Manual (SI2000 Document ID # 729569). Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 02-03-08-002 > Feb > 02 > Suspension - Front of Vehicle Too Low or Bottoms Out > Page 3077 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 02-03-08-002 > Feb > 02 > Suspension - Front of Vehicle Too Low or Bottoms Out Engine Mount: All Technical Service Bulletins Suspension - Front of Vehicle Too Low or Bottoms Out File in Section: 03 - Suspension Bulletin No.: 02-03-08-002 Date: February, 2002 TECHNICAL Subject: Front of Vehicle Sits Too Low, Bottoms Out Over Bumps (Replace Front Coil Springs, Inspect/Replace Frame and Mount) Models: 2000-2001 Chevrolet Impala with RPO 9C1 Police Car and 9C3 SEO Vehicle Police Car, Limited Content Built Prior to VIN Breakpoint 29140498 Condition Some customers may comment that the front of the vehicle sits too low and bottoms out over bumps. Cause This condition may be caused by the additional weight of the Police Package added to the vehicle. Correction Follow the service procedure below. Measuring J and K Trim Heights 1. Place the vehicle on a level surface such as an alignment rack. 2. Set the tire pressures on all Police vehicles. Tire Inflation Pressure Specifications Set the tire inflation pressure for Police Vehicles at 240 kPa (35 psi). 3. Verify the fuel level. Add additional weight if necessary to simulate a full tank. 4. Remove any additional items from the vehicle's interior. 5. Empty the rear compartment except for the spare tire. 6. Close the deck lid. 7. Close the doors 8. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 02-03-08-002 > Feb > 02 > Suspension - Front of Vehicle Too Low or Bottoms Out > Page 3083 Important: ^ Lift the front bumper at the center 38 mm (1.05 in) and gently release allowing the vehicle to settle. Push the bumper down 38 mm (1.05 in) and gently release allowing the vehicle to rise. Repeat this procedure for the rear bumper. ^ All dimensions are measured vertical to the ground. 9. Measure the J and K heights 230 mm-250 mm (9.06 in-9.84 in). If the J and K heights are below the specifications listed above, replace the front strut coil springs, P/N 22133025. Refer to Strut, Strut Component and/or Spring Replacement in the Service Manual (SI2000 Document ID # 652878). Frame Inspection/Replacement 1. Raise the vehicle. Important: ^ Vehicles with damage to the front frame rail due to impacts with an object are not covered under warranty. ^ Scrapes on the front frame rail will be covered under warranty. 2. Inspect the frame along the front edge for damage due to the vehicle bottoming out. 3. Inspect the frame for bending using a straight edge along the right side of the frame rail below the engine mount. 4. Remove the frame if the frame is damaged or bent. Refer to Frame Replacement in Body and Accessories in the Service Manual (SI2000 Document ID # 728902). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 02-03-08-002 > Feb > 02 > Suspension - Front of Vehicle Too Low or Bottoms Out > Page 3084 5. Remove the bolts retaining the engine mount bracket to the engine. 6. Remove the engine mount from the bracket. 7. Replace the engine mount bracket with P/N 10321856. 8. Install the engine mount to the bracket. Tighten Tighten the engine mount upper nuts to 78 N.m (58 lb ft). 9. Install the engine mount bracket with the engine mount to the engine. Tighten Tighten the engine mount bracket bolts to 102 Nm (75 lb ft). Important: ^ Replace the frame mounting bolts, P/N 10403403. ^ Only replace the frame insulators if necessary, front upper P/N 10402880, front lower P/N 10402882, rear upper P/N 10402881, and rear lower P/N 10299475. 10. Replace the frame, P/N 10322679. Refer to Frame Replacement in Body and Accessories in the Service Manual (SI2000 Document ID # 793554). 11. Align the vehicle. Refer to Wheel Alignment in the Service Manual (SI2000 Document ID # 729569). Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 02-03-08-002 > Feb > 02 > Suspension - Front of Vehicle Too Low or Bottoms Out > Page 3085 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 3086 Engine Mount: Specifications Engine Mount Bracket Bolt 43 ft.lb Engine Mount Lower Nut 32 ft.lb Engine Mount Strut and Lift Bracket Bolt Engine Left Rear 52 ft.lb Engine Mount Strut Bolt/Nut 35 ft.lb Engine Mount Strut Bracket Bolt Upper Radiator Support 21 ft.lb Engine Mount Strut Bracket Bolt Vehicle Right Side 37 ft.lb Engine Mount Upper Nut 35 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection Engine Mount: Service and Repair Engine Mount Inspection - Tools Required J28467-B Universal Engine Support Fixture - J 28467-90A Engine Support Adapters - J 36462-A Engine Support Adapter Leg Set Important: Before replacing any engine mount due to suspected fluid loss, verify that the source of the fluid is the engine mount, not the engine or accessories. 1. Install the J28467-B. Raise the engine in order to remove the weight from the engine mount and create slight tension in the rubber. 2. Observe the engine mount while raising the engine. Replace the engine mount if the engine mount exhibits any of the following conditions: - The hard rubber surface is covered with heat check cracks. - The rubber is separated from the metal plate of the engine mount. - The rubber is split through the center of the engine mount. 3. If there is movement between the metal plate of the engine mount and its attaching points, lower the engine on the engine mount. Tighten the bolts or nuts attaching the engine mount to the frame or engine mount bracket. Refer to Engine Mount and Bracket Replacement. 4. For information on the transaxle mount, refer to Automatic Transmission Mount Inspection in Transmission and Drivetrain. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3089 Engine Mount: Service and Repair Engine Mount Strut Bracket Replacement (Left) Removal Procedure 1. Remove the engine mount strut from the left engine mount strut bracket. Refer to Engine Mount Strut Replacement (Left) or Engine Mount Strut Replacement (Right). 2. Remove the engine exhaust crossover pipe. Refer to Exhaust Crossover Replacement. 3. Remove the thermostat housing. Refer to Thermostat Replacement in Cooling System. 4. Remove the engine mount strut bracket bolts from the left engine mount strut bracket to the cylinder head. 5. Remove the left engine mount strut bracket. Installation Procedure 1. Install the left engine mount strut bracket. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3090 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine mount strut bracket bolts through the engine mount strut bracket to the cylinder head. Tighten the engine mount strut bracket bolts to 70 Nm (52 ft. lbs.). 3. Install the thermostat housing. Refer to Thermostat Replacement in Cooling System. 4. Install the engine exhaust crossover pipe. Refer to Exhaust Crossover Replacement. 5. Install the engine mount strut to the left engine mount strut bracket. Refer to Engine Mount Strut Replacement (Left) or Engine Mount Strut Replacement (Right). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3091 Engine Mount: Service and Repair Engine Mount Strut Bracket Replacement (Right) Removal Procedure 1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 2. Remove the right engine mount strut from the right engine mount strut bracket. Refer to Engine Mount Strut Replacement (Left) or Engine Mount Strut Replacement (Right). 3. If equipped with oil cooler, remove the oil cooler pipe bracket bolt from the right engine mount strut bracket. 4. Reposition the air conditioning compressor. Refer to Compressor Replacement in Heating and Air Conditioning. 5. Remove the vertical bolt from the right engine mount strut bracket. 6. Remove the right engine mount strut bracket. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3092 1. Position the right engine mount strut bracket over the pin locator. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the vertical bolt through the right engine mount strut bracket to the cylinder head. Tighten the engine mount strut bracket bolt to 50 Nm (37 ft. lbs.). 3. Install the air conditioning compressor. Refer to Compressor Replacement in Heating and Air Conditioning. 4. If equipped with oil cooler, install the oil cooler pipe bracket bolt to the right engine mount strut bracket. Tighten the oil cooler pipe bracket bolt to 10 Nm (89 inch lbs.). 5. Install the right engine mount strut to the right engine mount strut bracket. Refer to Engine Mount Strut Replacement (Left) or Engine Mount Strut Replacement (Right). 6. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3093 Engine Mount: Service and Repair Engine Mount Strut Bracket Replacement (Upper) Removal Procedure 1. Remove the engine mount strut from the engine mount strut bracket at the upper radiator support. Refer to Engine Mount Strut Replacement (Left) or Engine Mount Strut Replacement (Right). 2. Remove the horizontal bolts (1) from the engine mount strut bracket. 3. Remove the vertical bolts (2) from the engine mount strut bracket. 4. Remove the engine mount strut bracket from the upper radiator support. Installation Procedure 1. Position the engine mount strut bracket over the upper radiator support. Make sure that the engine mount strut bracket and the engine mount strut Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3094 are aligned to the proper holes of the upper radiator support. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the vertical bolts (2) to the engine mount strut bracket. Tighten the engine mount strut bracket bolts to 28 Nm (21 ft. lbs.). 3. Install the horizontal bolts (1) to the engine mount strut bracket. Tighten the engine mount strut bracket bolt to 28 Nm (21 ft. lbs.). 4. Install the engine mount strut to the engine mount strut bracket at the upper radiator support. Refer to Engine Mount Strut Replacement (Left) or Engine Mount Strut Replacement (Right). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3095 Engine Mount: Service and Repair Engine Mount Inspection - Tools Required J28467-B Universal Engine Support Fixture - J 28467-90A Engine Support Adapters - J 36462-A Engine Support Adapter Leg Set Important: Before replacing any engine mount due to suspected fluid loss, verify that the source of the fluid is the engine mount, not the engine or accessories. 1. Install the J28467-B. Raise the engine in order to remove the weight from the engine mount and create slight tension in the rubber. 2. Observe the engine mount while raising the engine. Replace the engine mount if the engine mount exhibits any of the following conditions: - The hard rubber surface is covered with heat check cracks. - The rubber is separated from the metal plate of the engine mount. - The rubber is split through the center of the engine mount. 3. If there is movement between the metal plate of the engine mount and its attaching points, lower the engine on the engine mount. Tighten the bolts or nuts attaching the engine mount to the frame or engine mount bracket. Refer to Engine Mount and Bracket Replacement. 4. For information on the transaxle mount, refer to Automatic Transmission Mount Inspection in Transmission and Drivetrain. Engine Mount Strut Bracket Replacement (Left) Removal Procedure 1. Remove the engine mount strut from the left engine mount strut bracket. Refer to Engine Mount Strut Replacement (Left) or Engine Mount Strut Replacement (Right). 2. Remove the engine exhaust crossover pipe. Refer to Exhaust Crossover Replacement. 3. Remove the thermostat housing. Refer to Thermostat Replacement in Cooling System. 4. Remove the engine mount strut bracket bolts from the left engine mount strut bracket to the cylinder head. 5. Remove the left engine mount strut bracket. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3096 Installation Procedure 1. Install the left engine mount strut bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine mount strut bracket bolts through the engine mount strut bracket to the cylinder head. Tighten the engine mount strut bracket bolts to 70 Nm (52 ft. lbs.). 3. Install the thermostat housing. Refer to Thermostat Replacement in Cooling System. 4. Install the engine exhaust crossover pipe. Refer to Exhaust Crossover Replacement. 5. Install the engine mount strut to the left engine mount strut bracket. Refer to Engine Mount Strut Replacement (Left) or Engine Mount Strut Replacement (Right). Engine Mount Strut Bracket Replacement (Right) Removal Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3097 1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 2. Remove the right engine mount strut from the right engine mount strut bracket. Refer to Engine Mount Strut Replacement (Left) or Engine Mount Strut Replacement (Right). 3. If equipped with oil cooler, remove the oil cooler pipe bracket bolt from the right engine mount strut bracket. 4. Reposition the air conditioning compressor. Refer to Compressor Replacement in Heating and Air Conditioning. 5. Remove the vertical bolt from the right engine mount strut bracket. 6. Remove the right engine mount strut bracket. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3098 1. Position the right engine mount strut bracket over the pin locator. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the vertical bolt through the right engine mount strut bracket to the cylinder head. Tighten the engine mount strut bracket bolt to 50 Nm (37 ft. lbs.). 3. Install the air conditioning compressor. Refer to Compressor Replacement in Heating and Air Conditioning. 4. If equipped with oil cooler, install the oil cooler pipe bracket bolt to the right engine mount strut bracket. Tighten the oil cooler pipe bracket bolt to 10 Nm (89 inch lbs.). 5. Install the right engine mount strut to the right engine mount strut bracket. Refer to Engine Mount Strut Replacement (Left) or Engine Mount Strut Replacement (Right). 6. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. Engine Mount Strut Bracket Replacement (Upper) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3099 Removal Procedure 1. Remove the engine mount strut from the engine mount strut bracket at the upper radiator support. Refer to Engine Mount Strut Replacement (Left) or Engine Mount Strut Replacement (Right). 2. Remove the horizontal bolts (1) from the engine mount strut bracket. 3. Remove the vertical bolts (2) from the engine mount strut bracket. 4. Remove the engine mount strut bracket from the upper radiator support. Installation Procedure 1. Position the engine mount strut bracket over the upper radiator support. Make sure that the engine mount strut bracket and the engine mount strut are aligned to the proper holes of the upper radiator support. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3100 2. Install the vertical bolts (2) to the engine mount strut bracket. Tighten the engine mount strut bracket bolts to 28 Nm (21 ft. lbs.). 3. Install the horizontal bolts (1) to the engine mount strut bracket. Tighten the engine mount strut bracket bolt to 28 Nm (21 ft. lbs.). 4. Install the engine mount strut to the engine mount strut bracket at the upper radiator support. Refer to Engine Mount Strut Replacement (Left) or Engine Mount Strut Replacement (Right). Engine Mount Strut Replacement (Left) Removal Procedure 1. Remove the bolt and the nut from the engine mount strut at the left engine mount strut bracket on the engine. 2. Remove the bolt, the nut, and the engine wiring harness retainer from the engine mount strut at the engine mount strut bracket on the upper radiator support. 3. Remove the engine mount strut. 4. Inspect the rubber in the engine mount strut for the following conditions: - Hardness - Splitting - Cracking Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3101 1. Install the engine mount strut. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine wiring harness retainer, the bolt, and the nut to the engine runout strut at the engine mount strut bracket on the upper radiator support. Tighten the engine mount strut bolt to 48 Nm (35 ft. lbs.). 3. Install the bolt and the nut to the engine mount strut at the left engine mount strut bracket on the engine. Tighten the engine mount strut nut to 48 Nm (35 ft. lbs.). Engine Mount Strut Replacement (Right) Removal Procedure 1. Remove the bolt and the nut from the engine mount strut at the right engine mount strut bracket on the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3102 2. Remove the bolt and the nut from the engine mount strut at the engine mount strut bracket on the upper radiator support. 3. Remove the engine mount strut. 4. Inspect the rubber in the engine mount strut for the following conditions: - Hardness - Splitting - Cracking Installation Procedure 1. Install the engine mount strut. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolt and the nut to the engine mount strut at the engine mount strut bracket on the upper radiator support. Tighten the engine mount strut bolt to 48 Nm (35 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3103 3. Install the bolt and the nut to the engine mount strut at the right engine mount strut bracket on the engine. Tighten the engine mount strut nut to 48 Nm (35 ft. lbs.). Engine Support Fixture Installation Procedure - Tools Required J 28467-360 Engine Support Fixture - J 36462 Engine Support Adapter Leg 1. Raise the hood. 2. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 3. Remove the cross vehicle brace. Refer to Brace Replacement - Cross Vehicle in Body and Frame. 4. Install the thread support nuts (J 28467-33A) onto the strut attaching studs. 5. Install the strut tower support assemblies (J 28467-5A) over the thread support nuts (J 28467-33A). 6. Install the T-bolts (J 28467-53) with 5/16 inch washers through the strut tower support assemblies (J 28467-5A) into the thread support nuts (J 28467-33A) and hand tighten. 7. Install the two cross bracket assemblies (J 28467-1 A) over the strut tower tube (J 28467-3). 8. Install the strut tower tube (J 28467-3) into the strut tower support assemblies (J 28467-5A). 9. Install the 1/2 inch x 2.5 inch quick release pin (J 28467-10) through the strut tower support assemblies (J 28467-5A) and the strut tower tube (J 28467-3) on one side only. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3104 10. Install the radiator shelf tube (J 28467-2A) through the driver side cross bracket assembly (J 28467-1 A) on the top of the strut tower tube (J 28467-3). 11. Install the round tube of the front support assembly (J 28467-4A) through the large hole in the radiator shelf tube (J 28467-2A). The hole used in the radiator shelf tube (J 28467-2A) depends on the vehicle application. 12. Place the rubber padded foot of the front support assembly (J 28467-4A) on the vehicle radiator shelf. The foot position used in the front support assembly (J 28467-4A) depends on the vehicle application. 13. Install the 7/16 inch x 2.0 inch quick release pin (J 28467-9) through the hole in the front support assembly (J 28467-4A) in order to level the radiator shelf tube (J 28467-2A). The hole used in the front support assembly (J 28467-4A) depends on the vehicle application. 14. Install the lift hook (J 28467-7A) through the lift hook bracket (J 28467-6A). 15. Install the 1/2 inch lift hook washer and lift hook wing nut (J 28467-34) onto the lift hook (J 28467-7A). 16. Install the assembled lift hook bracket (J 28467-6A) over the radiator shelf tube (J 28467-2A). 17. Adjust the radiator shelf tube (J 28467-2A) and the assembled lift hook bracket (J 28467-6A) in order to align the hook with the left (front), rear of engine, lift hook bracket part of the left engine mount strut bracket. 18. Hand tighten the driver side cross bracket assembly (J 28467-11A) wing nuts. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3105 19. Install the second radiator shelf tube (J 28467-2A) through the passenger side cross bracket assembly (J 28467-11A) on the top of the strut tower tube (J 28467-3). 20. Install the round tube of the front support assembly (J 28467-4A) through the large hole in the radiator shelf tube (J 28467-2A). The hole used in the radiator shelf tube (J 28467-2A) depends on the vehicle application. 21. Place the rubber padded foot of the front support assembly (J 28467-4A) on the vehicle radiator shelf. The foot position used in the front support assembly (J 28467-4A) depends on the vehicle application. 22. Install the 7/16 inch x 2.0 inch quick release pin (J 28467-9) through the hole in the front support assembly (J 28467-4A) in order to level the radiator shelf tube (J 28467-2A). The hole used in the front support assembly (J 28467-4A) depends on the vehicle application. 23. Install the lift hook (J 28467-7A) through the lift hook bracket (J 28467-6A). 24. Install the 1/2 inch lift hook washer and lift hook wing nut (J 28467-34) onto the lift hook (J 28467-7A). 25. Install the assembled lift hook bracket (J 28467-6A) over the radiator shelf tube (J 28467-2A). 26. Adjust the radiator shelf tube (J 28467-2A) and the assembled lift hook bracket (J 28467-6A) in order to align the hook with the right (rear), front of engine, lift hook bracket located next to the generator. 27. Hand tighten the passenger side cross bracket assembly (J 28467-1 A) wing nuts. 28. Hand tighten the lift hook wing nuts (J 28467-34) securely to remove all slack from the engine support fixture assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure - Warm ............................................................................................................................ .................................................. 15psi @ 1100 RPM Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 3110 Engine Oil Pressure: Testing and Inspection Low or No Oil Pressure The following conditions may cause low or no oil pressure: Low oil level Fill to the full mark on the oil level indicator. - Incorrect or malfunctioning oil pressure switch Replace the oil pressure switch. - Incorrect or malfunctioning oil pressure gauge Replace the oil pressure gauge. - Improper oil viscosity or diluted oil Install oil of proper viscosity for expected temperature. - Install new oil if the oil is diluted. - A worn or dirty oil pump Clean or replace the oil pump. - A plugged oil filter Replace the oil filter. - A loose or plugged oil pickup screen Replace the oil pickup screen. - A hole in the oil pickup tube Replace the oil pickup tube. - Excessive bearing clearance Replace the bearings. - Cracked, porous, or plugged oil gallery Repair or replace the engine block. - Missing or improperly installed gallery plugs Install or repair the plugs as needed. - A stuck pressure regulator valve Inspect the pressure regulator valve for sticking in the bore. - Inspect the bore for scoring and burrs. - A worn or poorly machined camshaft Replace the camshaft. - Worn valve guides Repair the valve guides as needed. Oil Pressure Testing - Tools Required J 25087-C Oil Pressure Test Kit If the vehicle has low oil pressure complete the following steps: 1. Inspect the oil level. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the oil filter. 4. Assemble the plunger valve in the large hole of the J 25087-C base. Insert the hose in the small hole of the J 25087-C base. Connect the gauge to the end of the hose. 5. Insert the flat side of the rubber plug in the bypass valve without depressing the bypass valve. 6. Install the J 25087-C on the filter mounting pad. 7. Start the engine. 8. Inspect the overall oil pressure, the oil pressure switch, and for noisy lifters. Ensure that the engine is at operating temperature before inspecting the oil pressure. The oil pressure should be approximately 414 kPa (60 psi) at 1,850 RPM using 5W-30 engine oil. 9. If adequate oil pressure is indicated, test the oil pressure switch. 10. If a low reading is indicated, press the valve on the tester base in order to isolate the oil pump and/or its components from the lubricating system. An adequate reading at this time indicates a good pump and the previous low pressure was due to worn bearings, etc. A low reading while pressing the valve indicates a faulty pump. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications Engine Oil Dip Stick - Dip Stick Tube: Specifications Oil Level Indicator Tube Bolt 18 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications > Page 3114 Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Removal Procedure 1. Disconnect the spark plug wire from the spark plug adjacent to the oil level indicator tube. 2. Remove the oil level indicator. 3. Remove the oil level indicator tube bracket bolt from the oil level indicator tube bracket. 4. Remove the oil level indicator tube. Installation Procedure 1. Clean the oil level indicator tube. 2. Apply sealant around the oil level indicator tube 12.7 mm (0.50 inch) below the bead. Use GM sealant P/N 12345739 or the equivalent. 3. Install the oil level indicator tube into the engine block. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt to the oil level indicator tube bracket. Tighten the oil level indicator tube bracket bolt to 25 Nm (18 ft. lbs.). 5. Install the oil level indicator. 6. Connect the spark plug wire to the spark plug adjacent to the oil level indicator tube. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 3119 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 3120 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 4.2L (4.5 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 3123 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Grade ............................................................... ..................................................................................................... 5W-30 (preferred), 10W-30 if above 0° F Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 3124 Engine Oil: Service Precautions Look for and use ONLY engine oil that meets GM Specification. Oil that does not have the correct specification designation can cause engine damage not covered by warranty. Do NOT use engine oil additives. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications Oil Cooler: Specifications Oil Cooler Connector 37 ft.lb Oil Cooler Hose Fitting 14 ft.lb Oil Cooler Pipe Bracket Bolt 89 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 3132 Oil Filter: Specifications Oil Filter 115 in.lb Oil Filter Bypass Hole Plug 14 ft.lb Oil Filter Fining 29 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 3133 Oil Filter: Service and Repair Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Position the oil drain pan under the engine oil drain plug. 3. Remove the engine oil pan drain plug. 4. Clean and inspect the engine oil pan drain plug, repair or replace if necessary. 5. Clean and inspect the engine oil pan drain plug sealing surface on the oil pan, repair or replace oil pan if necessary. 6. Remove the oil filter. 7. Clean and inspect the oil filter sealing area on the engine block, repair or replace if necessary. Installation Procedure 1. Lightly oil the replacement oil filter gasket with clean oil. Refer to Maintenance Items. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 3134 2. Install the new oil filter. Tighten the new oil filter to 3/4 to 1 full turn, after the oil filter gasket contacts the oil filter mounting surface. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the engine oil pan drain plug. Tighten the engine oil pan drain plug to 25 Nm (18 ft. lbs.). 4. Remove the oil drain pan. 5. Lower the vehicle. 6. Fill the engine with new engine oil. Refer to Capacities - Approximate Fluid. 7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the oil level indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, readjust the oil level by adding or draining the engine oil. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair Oil Filter Adapter: Service and Repair Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the oil filter. Refer to Engine Oil and Oil Filter Replacement. 3. Remove the oil filter bypass valve. Refer to Oil Filter Adapter Removal. Installation Procedure 1. Install the oil filter bypass valve. Refer to Oil Filter Adapter Installation. 2. Lower the vehicle. 3. Add engine oil as required. Refer to Engine Oil and Oil Filter Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Description and Operation Oil Level Warning Indicator: Description and Operation Engine Oil Level Switch The PCM monitors the engine oil level switch signal at start-up to determine if the engine oil is OK. If the PCM determines that a low oil level condition exists, the PCM will communicate the information over the Class II circuit to the P cluster and it will illuminate the indicator lamp or initiate a message. The low oil level message may not appear if other messages are being commanded, such as the rear deck lid, driver or passenger doors ajar. Ensure that all doors and compartment lids are completely closed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Specifications Oil Level Sensor: Specifications Oil Level Sensor Bolt 89 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Specifications > Page 3144 Oil Level Sensor: Locations Locations View Front center of the engine oil pan. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor For ECM > Component Information > Locations Oil Level Sensor For ECM: Locations Front center of the engine oil pan. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor For ECM > Component Information > Locations > Page 3148 Engine Oil Level Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolt 18 ft.lb Oil Pan Drain Plug 18 ft.lb Oil Pan Side Bolt 37 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 3152 Oil Pan: Service and Repair Removal Procedure - Tools Required J 28467-360 Engine Support Fixture - J 28467-90A Engine Support Fixture Adapter - J 36462-A Engine Support Adapter Leg - J 39505 Torque Wrench Adapter 1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 2. Remove the engine mount struts from the engine. Refer to Engine Mount Strut Replacement (Left) and Engine Mount Strut Replacement (Right). 3. Disconnect the A/C compressor mounting bolts. Reposition and secure the A/C compressor. Refer to Compressor Replacement in Heating and Air Conditioning. 4. Install the J28467-360. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Disconnect the three-way catalytic converter pipe from the right exhaust manifold. Refer to Catalytic Converter Replacement in Powertrain Management. 7. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement. 8. Disconnect the oil level sensor wiring harness connection. 9. Remove the starter motor. Refer to Starter Motor Replacement in Starting and Charging. 10. Remove the transaxle brace from the oil pan. Refer to Automatic Transmission Brace Replacement in Transmission and Drivetrain. 11. Remove the transaxle mount lower nuts. Refer to Automatic Transmission Mount Replacement in Transmission and Drivetrain. 12. Remove the engine mount lower nuts. Refer to Engine Mount and Bracket Replacement. 13. Lower the vehicle. 14. Use the J 28467-360 in order to raise the engine. 15. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 16. Remove the engine mount bracket with the engine mount from the oil pan. Refer to Engine Mount and Bracket Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 3153 17. Use the J 39505 in order to remove the right oil pan side bolts. 18. Remove the left oil pan side bolts. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 3154 19. Remove the oil pan retaining bolts. 20. Remove the oil pan. 21. Remove the oil pan gasket. 22. Clean the oil pan and the engine block gasket surface. Installation Procedure - Tools Required J 39505 Torque Wrench Adapter 1. Apply sealant at the rear main bearing cap and the engine block (1). 2. Install the oil pan gasket. Refer to Oil Pan Installation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 3155 3. Install the oil pan. Install the oil pan retaining bolts. Refer to Oil Pan Installation. 4. Install the left oil pan side bolts. Refer to Oil Pan Installation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 3156 5. Use the J 39505 in order to install the right oil pan side bolts. Refer to Oil Pan Installation. 6. Install the engine mount bracket with the engine mount to oil pan. Refer to Engine Mount and Bracket Replacement. 7. Lower the vehicle. 8. Use the J 28467-360 in order to lower the engine. 9. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 10. Install the transaxle mount lower nuts. Refer to Automatic Transmission Mount Replacement in Transmission and Drivetrain. 11. Install the engine mount lower nuts. Refer to Engine Mount and Bracket Replacement. 12. Install the transaxle brace to the oil pan. Refer to Automatic Transmission Brace Replacement in Transmission and Drivetrain. 13. Install the starter motor. Refer to Starter Motor Replacement in Starting and Charging. 14. Install the oil level sensor wiring harness connection. 15. Install the three-way catalytic converter pipe to the right exhaust manifold. Refer to Catalytic Converter Replacement in Powertrain Management. 16. Lower the vehicle. 17. Remove the J 28467-360 the J 36462-A and the J 28467-90A. 18. Install the A/C compressor. Refer to Compressor Replacement in Heating and Air Conditioning. 19. Install the engine mount struts to the engine. Refer to Engine Mount Strut Replacement (Left) and Engine Mount Strut Replacement(Right). 20. Fill the engine with new engine oil. Refer to Engine Oil and Oil Filter Replacement. 21. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Engine Oil Pressure Indicator Switch 115 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 3160 Engine Oil Pressure Indicator Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations > Page 3164 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Component Locations Oil Pressure Switch (For Fuel Pump): Component Locations Engine Oil Pressure Indicator Switch (LA1) Front of the engine, above the starter. RPO LA1: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Engine Oil Pressure Indicator Switch (L36) Near generator. RPO L36: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Component Locations > Page 3169 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Component Locations > Page 3170 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 3171 Oil Pressure Switch (For Fuel Pump): Description and Operation Engine Oil Pressure Switch The PCM monitors the engine oil pressure switch (1) signal to determine if the engine oil pressure is OK. If the PCM determines that a low oil pressure condition exists, the PCM will communicate the information over the Class II circuit to the P cluster and it will illuminate the indicator lamp or initiate a message. The low oil pressure message may not appear if other messages are being commanded, such as the rear deck lid, driver or passenger doors ajar. Ensure that all doors and compartment lids are completely closed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Cover > Component Information > Specifications Oil Pump Cover: Specifications Oil Pump Cover Bolt 89 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Drive Shaft > Component Information > Specifications Oil Pump Drive Shaft: Specifications Oil Pump Drive Clamp Bolt .................................................................................................................. ............................................................ 27 ft. lbs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Drive Shaft > Component Information > Specifications > Page 3178 Oil Pump Drive Shaft: Service and Repair Removal Procedure 1. Remove the upper intake manifold. Refer to Intake Manifold Replacement (Upper) or Intake Manifold Replacement (Lower). 2. Remove the fuel return pipe to the fuel injector rail. Refer to Fuel Rail Assembly Replacement in Computers and Controls. 3. Remove the fuel feed pipe to the fuel injector rail. Refer to Fuel Rail Assembly Replacement in Computers and Controls. 4. Remove the fuel pipe clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Drive Shaft > Component Information > Specifications > Page 3179 5. Remove the fuel pipe clip bolt. 6. Remove the oil pump drive bolt. 7. Remove the oil pump drive clamp. 8. Remove the oil pump drive. 9. Remove the oil pump drive seal. Installation Procedure 1. Install the oil pump drive seal. Coat the seal or bore in the engine block with engine oil. 2. Install the oil pump drive. Refer to Oil Pump Drive Installation. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Drive Shaft > Component Information > Specifications > Page 3180 3. Install the oil pump drive clamp. Install the oil pump drive bolt. Refer to Oil Pump Drive Installation. 4. Connect the fuel return pipe to the fuel injector rail. Refer to Fuel Rail Assembly Replacement in Computers and Controls. 5. Connect the fuel feed pipe to the fuel injector rail. Refer to Fuel Rail Assembly Replacement in Computers and Controls. 6. Install the fuel pipe clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Drive Shaft > Component Information > Specifications > Page 3181 7. Install the fuel pipe clip bolt. Tighten the fuel pipe clip bolt to 8 Nm (71 inch lbs.). 8. Install the upper intake manifold. Refer to Intake Manifold Replacement (Upper) or Intake Manifold Replacement (Lower). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure - Warm ............................................................................................................................ .................................................. 15psi @ 1100 RPM Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 3186 Engine Oil Pressure: Testing and Inspection Low or No Oil Pressure The following conditions may cause low or no oil pressure: Low oil level Fill to the full mark on the oil level indicator. - Incorrect or malfunctioning oil pressure switch Replace the oil pressure switch. - Incorrect or malfunctioning oil pressure gauge Replace the oil pressure gauge. - Improper oil viscosity or diluted oil Install oil of proper viscosity for expected temperature. - Install new oil if the oil is diluted. - A worn or dirty oil pump Clean or replace the oil pump. - A plugged oil filter Replace the oil filter. - A loose or plugged oil pickup screen Replace the oil pickup screen. - A hole in the oil pickup tube Replace the oil pickup tube. - Excessive bearing clearance Replace the bearings. - Cracked, porous, or plugged oil gallery Repair or replace the engine block. - Missing or improperly installed gallery plugs Install or repair the plugs as needed. - A stuck pressure regulator valve Inspect the pressure regulator valve for sticking in the bore. - Inspect the bore for scoring and burrs. - A worn or poorly machined camshaft Replace the camshaft. - Worn valve guides Repair the valve guides as needed. Oil Pressure Testing - Tools Required J 25087-C Oil Pressure Test Kit If the vehicle has low oil pressure complete the following steps: 1. Inspect the oil level. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the oil filter. 4. Assemble the plunger valve in the large hole of the J 25087-C base. Insert the hose in the small hole of the J 25087-C base. Connect the gauge to the end of the hose. 5. Insert the flat side of the rubber plug in the bypass valve without depressing the bypass valve. 6. Install the J 25087-C on the filter mounting pad. 7. Start the engine. 8. Inspect the overall oil pressure, the oil pressure switch, and for noisy lifters. Ensure that the engine is at operating temperature before inspecting the oil pressure. The oil pressure should be approximately 414 kPa (60 psi) at 1,850 RPM using 5W-30 engine oil. 9. If adequate oil pressure is indicated, test the oil pressure switch. 10. If a low reading is indicated, press the valve on the tester base in order to isolate the oil pump and/or its components from the lubricating system. An adequate reading at this time indicates a good pump and the previous low pressure was due to worn bearings, etc. A low reading while pressing the valve indicates a faulty pump. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement > Page 3191 Intake Manifold: Technical Service Bulletins Intake Manifold (Lower) - Revised Installation File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-014 Date: April, 2002 SERVICE MANUAL UPDATE Subject: Revised Lower Intake Manifold Installation Models: 1996 Buick Regal 1996-1998 Buick Skylark 1996-2002 Buick Century 2002 Buick Rendezvous 1996 Chevrolet Beretta, Corsica, Lumina APV 1996-2001 Chevrolet Lumina 1997-2002 Chevrolet Malibu, Monte Carlo, Venture 2000-2002 Chevrolet Impala 1996-1998 Oldsmobile Achieva 1997-1998 Oldsmobile Cutlass 1996-2002 Oldsmobile Silhouette 1999-2002 Oldsmobile Alero 1996-1998 Pontiac TransSport 1996-2002 Pontiac Grand Am, Grand Prix 1999-2002 Pontiac Montana 2001-2002 Pontiac Aztek with 3.1L or 3.4L Engine (VINs J, M, E RPOs LG8, L82, LA1) This bulletin is being issued to revise Steps 1 and 2 of the Lower Intake Manifold Installation procedure in the Engine Mechanical sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Intake Manifold Installation - Lower Important: All gasket mating surfaces need to be free of oil and foreign material. Use GM P/N 12346139 (in Canada, use GM P/N 10953463) or the equivalent to clean surfaces. 1. Install the intake manifold gaskets. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement > Page 3192 2. Apply small drops (8-10 mm [0.31-0.39 in]) of RTV sealer, GM P/N 12346286 (in Canada, use GM P/N 10953476) or the equivalent to the four corners of the intake manifold to block joint (1). 3. Connect the small drops with a bead of RTV sealer that is between 8-10 mm (0.31-0.39 in) wide and 3.0-5.0 mm (0.12-0.20 in) thick (2). The remaining steps on the original bulletin remain unchanged. DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Throttle Body Torque & Sequence Intake Manifold: Specifications Throttle Body Bolt/Stud 18 lb. ft. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Throttle Body Torque & Sequence > Page 3195 Intake Manifold: Specifications Torque & Tightening Sequence Lower Intake Manifold Install NEW lower intake manifold bolts. The torque specification is a 2-step process; tighten the vertical lower intake manifold bolts (the four middle ones) to 7 Nm (62 lb in). Tighten the diagonal lower intake manifold bolts (two on each end) to 7 Nm (62 lb in). Tighten the vertical lower intake manifold bolts (the four middle ones) to 13 Nm (115 lb in). Tighten the diagonal lower intake manifold bolts (two on each end) to 25 Nm (18 lb ft). Upper Intake Manifold Tighten Bolt/stud .................................................................................................................................. .................................................... 25 Nm (18 ft. lbs) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement Intake Manifold: Service and Repair Lower Intake Manifold Replacement Removal Procedure Important: This engine uses a sequential multiport fuel injection system. Injector wiring harness connectors must be connected to their appropriate fuel injector or exhaust emissions and engine performance may be seriously affected. 1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 2. Remove the upper intake manifold. Refer to Intake Manifold Replacement (Upper) or Intake Manifold Replacement (Lower). 3. Remove the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement (Left Front) or Valve Rocker Arm Cover Replacement (Right Rear). 4. Remove the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement (Left Front) or Valve Rocker Arm Cover Replacement (Right Rear). 5. Disconnect the engine coolant temperature (ECT) wiring harness. 6. Disconnect and remove the fuel injector and manifold air pressure (MAP) wiring harness. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement > Page 3198 7. Remove the fuel pipe clip bolt. 8. Remove the fuel pipe clip. 9. Disconnect the fuel feed pipe from the fuel injector rail. Refer to Fuel Rail Assembly Replacement in Computers and Controls. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement > Page 3199 10. Disconnect the fuel return pipe from the fuel injector rail. Refer to Fuel Rail Assembly Replacement in Computers and Controls. 11. Remove the fuel injector rail. Refer to Fuel Rail Assembly Replacement in Computers and Controls. 12. Disconnect the power steering pump from the front engine cover and position aside. Refer to Power Steering Pump Replacement in Steering and Suspension. 13. Disconnect the heater inlet pipe with heater hose from the lower intake manifold and reposition. 14. Disconnect the radiator inlet hose from the engine. Refer to Radiator Hose Replacement - Inlet in Cooling System. 15. Disconnect the thermostat bypass hose from the thermostat bypass pipe and lower intake manifold pipe. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement > Page 3200 16. Remove the lower intake manifold bolts. 17. Remove the lower intake manifold. 18. Remove the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Removal. 19. Remove the lower intake manifold gaskets and seals. 20. Clean the lower intake manifold gasket and seal surfaces on the cylinder heads and the engine block. 21. Clean the gasket and seal surfaces on the lower intake manifold with degreaser. 22. Remove all the loose RTV sealer. 23. If replacing the lower intake manifold remove the engine coolant temperature (ECT) sensor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement > Page 3201 24. If replacing the lower intake manifold remove the water outlet bolts. 25. Remove the water outlet. 26. If replacing the lower intake manifold remove the thermostat. Installation Procedure 1. If removed install the thermostat. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement > Page 3202 2. If removed install the water outlet. Install the water outlet bolts. Refer to Water Outlet Installation. 3. If removed install the engine coolant temperature (ECT) sensor. Tighten the engine coolant temperature (ECT) sensor to 23 Nm (17 lb ft). Note: Refer to TSB# 03-06-01-010B (10/24/2003) for updated information about a new intake manifold gasket and installation procedure. 4. Install the lower intake manifold gaskets. 5. Install the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Installation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement > Page 3203 6. Install the lower intake manifold. 7. Install NEW lower intake manifold bolts. Revised Updated Torque Specification, Bulletin #vss20030024 The torque specification is a 2-step process; tighten the vertical lower intake manifold bolts (the four middle ones) to 7 Nm (62 lb in). Tighten the diagonal lower intake manifold bolts (two on each end) to 7 Nm (62 lb in).Tighten the vertical lower intake manifold bolts (the four middle ones) to 13 Nm (115 lb in). Tighten the diagonal lower intake manifold bolts (two on each end) to 25 Nm (18 lb ft). 8. Connect the thermostat bypass hose to the thermostat bypass pipe and lower intake manifold pipe. 9. Connect the radiator inlet hose to the engine. Refer to Radiator Hose Replacement -Inlet in Cooling System. 10. Connect the heater inlet pipe and heater hose to the lower intake manifold. 11. Install the power steering pump to the front engine cover. Refer to Power Steering Pump Replacement in Steering and Suspension. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement > Page 3204 12. Install the fuel injector rail. Refer to Fuel Rail Assembly Replacement in Computers and Controls. 13. Connect the fuel return pipe to the fuel injector rail. Refer to Fuel Rail Assembly Replacement in Computers and Controls. 14. Connect the fuel feed pipe to the fuel injector rail. Refer to Fuel Rail Assembly Replacement in Computers and Controls. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement > Page 3205 15. Install the fuel pipe clip. 16. Install the fuel pipe clip bolt. Tighten the fuel pipe clip bolt to 8 Nm (71 lb in). 17. Connect the fuel injector and manifold air pressure (MAP) wiring harness. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement > Page 3206 18. Connect the engine coolant temperature (ECT) wiring harness. 19. Install the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement (Left Front) or Valve Rocker Arm Cover Replacement (Right Rear). 20. Install the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement (Left Front) or Valve Rocker Arm Cover Replacement (Right Rear). 21. Install the upper intake manifold. Refer to Intake Manifold Replacement (Upper) or Intake Manifold Replacement (Lower). 22. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement > Page 3207 Intake Manifold: Service and Repair Upper Intake Manifold Replacement Removal Procedure Important: This engine uses a sequential multiport fuel injection system. Connect the injector wiring harness connectors to their appropriate fuel injector or exhaust emissions and engine performance may be seriously affected. 1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 2. Carefully disconnect the vacuum hose connection from the throttle body air inlet duct. 3. Disconnect the wiring harness connection from the intake air temperature (IAT) sensor in the throttle body air inlet duct. Refer to IAT Sensor Replacement in Computers and Controls. 4. Carefully disconnect the throttle body air inlet duct. 5. Drain the engine coolant from the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 6. Remove the accelerator control and cruise control cables with bracket from the throttle body. Refer to Accelerator Controls Cable Bracket Replacement in Computers and Controls. 7. Disconnect the wiring harness connectors from the throttle body: - Throttle position (TP) sensor - Idle air control (IAC) valve 8. Disconnect the wiring harness attachment clips. - Camshaft position (CMP) sensor wiring harness - Left spark plug wire harness 9. Disconnect the thermostat bypass pipe coolant hoses from the throttle body. 10. Remove the rear generator brace. Refer to Generator Brace Replacement in Starting and Charging. 11. Remove the following components: 11.1. The vacuum lines at the upper intake manifold 11.2. The MAP sensor 11.3. The EGR valve 11.4. The spark plug wires 11.5. The ignition control module 11.6. The upper intake manifold 11.7. The upper intake manifold gaskets Refer to Intake Manifold Removal (Upper) or Intake Manifold Removal (Lower). 12. Remove the throttle body. Refer to Throttle Body Assembly Replacement in Computers and Controls. 13. Clean the seal surfaces on the manifold with degreaser. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement > Page 3208 1. Install the throttle body. Refer to Throttle Body Assembly Replacement in Computers and Controls. 2. Install the following components: 2.1. The upper intake manifold gaskets 2.2. The upper intake manifold 2.3. The ignition control module 2.4. The spark plug wires 2.5. The EGR valve 2.6. The MAP sensor 2.7. The vacuum lines at the upper intake manifold Refer to Intake Manifold Installation (Lower) or Intake Manifold Installation (Upper). 3. Install the rear generator brace. Refer to Generator Brace Replacement in Starting and Charging. 4. Connect the thermostat bypass pipe coolant hoses to the throttle body. 5. Connect the wiring harness connectors to the throttle body. - Throttle position (TP) sensor - Idle air control (IAC) valve 6. Install the accelerator control and cruise control cables with bracket to the throttle body. Refer to Accelerator Controls Cable Bracket Replacement in Computers and Controls. 7. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 8. Install the throttle body air inlet duct. 9. Connect the wiring harness connection to the intake air temperature (IAT) sensor in the throttle body air inlet duct. Refer to IAT Sensor Replacement in Computers and Controls. 10. Connect the vacuum hose connection to the throttle body air inlet duct. 11. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Description and Operation Oil Level Warning Indicator: Description and Operation Engine Oil Level Switch The PCM monitors the engine oil level switch signal at start-up to determine if the engine oil is OK. If the PCM determines that a low oil level condition exists, the PCM will communicate the information over the Class II circuit to the P cluster and it will illuminate the indicator lamp or initiate a message. The low oil level message may not appear if other messages are being commanded, such as the rear deck lid, driver or passenger doors ajar. Ensure that all doors and compartment lids are completely closed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Service and Repair Camshaft Oil Seal: Service and Repair Removal Procedure 1. Remove the engine flywheel. Refer to Engine Flywheel Replacement. 2. Remove the camshaft rear bearing hole plug. Installation Procedure 1. Install the camshaft rear bearing hole plug. Refer to Camshaft Bearing Installation. Make sure that the camshaft rear bearing plug is installed to specifications. 2. Install the engine flywheel. Refer to Engine Flywheel Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Main Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal Crankshaft Main Bearing Seal: Customer Interest Engine - Oil Leaks from Crankshaft Rear Main Seal Bulletin No.: 05-06-01-019F Date: October 02, 2007 TECHNICAL Subject: Engine Oil Leak at Crankshaft Rear Main Oil Seal (Install Revised Crankshaft Rear Main Oil Seal Using Revised Rear Main Seal Installer and Remover Tools) Models: 1986-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) with 2.8L, 3.1L, 3.4L, 3.5L, 3.9L 60 Degree V6 Engine (VINs D, E, F, J, K, L, M, N, R, S, T, V, W, X, Z, 1, 3, 8, 9, W, R - RPOs LG6, LA1, LNJ, LG8, LL1 or LX9, L82, LL2, LB8, LHO, LG5, LB6, LE2 or LQ1, LH7, LC1, L44, LZ4, LZE, LZ9, LGD, LZ8, LZG) Supercede: This bulletin is being revised to add an Important statement on proper seal installation. Please discard Corporate Bulletin Number 05-06-01-019E (Section 06 - Engine/Propulsion System). This bulletin only applies to 60 degree V6 engines. Some of the discontinued 60 degree V6 engine VINs and RPOs may have carried over to other new model year engines and may no longer be a 60 degree V6 engine. So this bulletin may not apply. It is very important to verify that the following information is correct before using this bulletin: Year of vehicle (e.g. N = 1992) V6 Engine Liter size (e.g. 3.4L) VIN CODE (e.g. X) RPO (e.g. LQ1) If ALL the information from the vehicle (year, size, VIN Code, RPO) you're working on can be found under the models listed above, then this bulletin applies to that engine. If one or more of the vehicle's information can NOT be found under the models listed above, then this bulletin does NOT apply. This bulletin does not apply to 2004-2007 Saturn VUE models with 3.5L DOHC V6 Engine (VIN 4 RPO L66) or 2005-2008 Cadillac CTS with 2.8L HFV6 Engine (VIN T - RPO LP1). Condition Some customers may comment on external oil leakage. Correction Before replacement of the new design crankshaft rear main oil seal, be sure the PCV system is operating correctly. The new seal described below comes with a protective nylon sleeve already installed in the seal. This sleeve assures that the seal is installed in the correct direction and also protects the seal from getting damaged during installation. Do not remove the protective sleeve from the seal; if removed, the installation tool (EN48108) will not work. A new design crankshaft rear main oil seal and installation tool (EN-48108) has been released. This seal incorporates features that improve high mileage durability. Replace the crankshaft rear main oil seal with the new design rear main oil seal, P/N 12592195, using the following service procedures. Tools Required TOOLS WERE SHIPPED TO YOUR DEALERSHIPS. IF YOU HAVE NOT RECEIVED THEM OR THEY ARE LOST, PLEASE CALL GM SPECIAL SERVICE TOOLS AT 1-800-GM-TOOLS. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Main Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3225 EN-48108 Rear Main Oil Seal Installation Tool This tool has a unique design to allow the technician to easily install the rear main seal squarely to the correct depth and direction. Before proceeding with installation, review the above illustration to become familiar with the components shown in the illustration. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Main Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3226 EN-48672 rear Main Oil Seal Remover Tool This tool has a unique design to allow the technician to easily remove the rear main seal without nicking the crankshaft sealing surface when removing the seal. Before proceeding with removal, review the above illustration to become familiar with the following components: Removal Plate Threaded Adjustment Pins and Jam Nuts Force Screw # 2 Self Drill Screws 38 mm (1.5 in) long 8 needed Extreme Pressure Lubricant Removal Procedure Remove the transmission. Refer to Transmission Replacement in SI or the appropriate Service Manual. Remove the engine flywheel. Refer to Engine Flywheel Replacement in SI or the appropriate Service Manual. Install the removal plate (2) and both threaded adjustment pins and jam nuts (1) into the back of the crankshaft flange and secure the plate with adjustment pins and jam nuts. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Main Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3227 Install # 2 Self Drill Screws 38 mm (1.5 in) long, eight needed, (1) and tighten down flush to the plate. Before installing the force screw, apply a small amount of the Extreme Pressure Lubricant J 23444-A, provided in the tool kit. Install the force screw (1) and back off both jam nuts (2) and continue to turn the force screw (1) into the removal plate to remove the seal from the crankshaft. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Main Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3228 Once the seal is removed from the crankshaft, remove and save all eight screws and discard the old seal. Clean the crankshaft sealing surface with a clean, lint free towel. Inspect the lead-in edge of the crankshaft for burrs or sharp edges that could damage the rear main oil seal. Remove any burrs or sharp edges with crocus cloth or equivalent before proceeding. Installation Procedure Do not remove the protective nylon sleeve from the new rear main seal prior to installation. The EN-48108 is designed to install the rear main seal with the protective sleeve in place. Never apply or use any oil, lubricants or sealing compounds on the crankshaft rear main oil seal. Align the mandrel dowel pin (EN-48108) to the dowel pin hole in the crankshaft. Refer to the above illustration. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Main Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3229 Using a large flat-bladed screwdriver, tighten the two mandrel screws to the crankshaft. Ensure that the mandrel is snug to the crankshaft hub. Refer to the above illustration. Different types (styles) of rear main seals were used in production in different model years, engines and manufacturing facilities. As a result, the NEW style rear main seal that you will be installing may have a different appearance or shape than the one removed. Regardless of what type of seal was removed and what side was facing outside the engine, the new seal must be installed as described. Upon close inspection of the outer lip on the new seal, the words this side out" will be seen. This side of the seal must be facing OUTSIDE the engine when correctly installed. While this may seem backwards, it is correct. In addition, the protective nylon (plastic) sleeve that the seal is mounted on in the package was designed so that the seal can only be installed in the proper direction when using the installation tool described in the following steps. Install the rear main seal (1), with the protective nylon sleeve attached (2), onto the mandrel. The seal, if properly installed, will center on a step that protrudes from the center of the mandrel. As an error proof, seal will fit only one way onto the mandrel. Refer to the above illustration. Before installing the outer drive drum, bearing, washer and the drive nut onto the threaded shaft, apply a small amount of the Extreme Pressure Lubricant J 23444-A, provided in the tool kit. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Main Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3230 Install the outer drive drum onto the mandrel (EN-481 08). Install the bearing, washer and the drive nut onto the threaded shaft. Refer to the above illustration. Using a wrench, turn the drive nut on the mandrel (EN-48108), which will push the seal into the engine block bore. Turn the wrench until the drive drum is snug and flush against the engine block. Refer to the above illustration. Loosen and remove the drive nut, washer, bearing and drive drum. Discard the protective nylon sleeve. Verify that the seal has seated properly. Use a flat-bladed screwdriver to remove the two attachment screws from the mandrel and remove the mandrel from the crankshaft hub. Refer to the above illustration. Install the engine flywheel. Refer to Engine Flywheel Replacement in SI or the appropriate Service Manual. Install the transmission. Refer to Transmission Replacement in SI or the appropriate Service Manual. Inspect for proper fluid levels. Inspect for leaks. Parts Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Main Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3231 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Main Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal Crankshaft Main Bearing Seal: All Technical Service Bulletins Engine - Oil Leaks from Crankshaft Rear Main Seal Bulletin No.: 05-06-01-019F Date: October 02, 2007 TECHNICAL Subject: Engine Oil Leak at Crankshaft Rear Main Oil Seal (Install Revised Crankshaft Rear Main Oil Seal Using Revised Rear Main Seal Installer and Remover Tools) Models: 1986-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) with 2.8L, 3.1L, 3.4L, 3.5L, 3.9L 60 Degree V6 Engine (VINs D, E, F, J, K, L, M, N, R, S, T, V, W, X, Z, 1, 3, 8, 9, W, R - RPOs LG6, LA1, LNJ, LG8, LL1 or LX9, L82, LL2, LB8, LHO, LG5, LB6, LE2 or LQ1, LH7, LC1, L44, LZ4, LZE, LZ9, LGD, LZ8, LZG) Supercede: This bulletin is being revised to add an Important statement on proper seal installation. Please discard Corporate Bulletin Number 05-06-01-019E (Section 06 - Engine/Propulsion System). This bulletin only applies to 60 degree V6 engines. Some of the discontinued 60 degree V6 engine VINs and RPOs may have carried over to other new model year engines and may no longer be a 60 degree V6 engine. So this bulletin may not apply. It is very important to verify that the following information is correct before using this bulletin: Year of vehicle (e.g. N = 1992) V6 Engine Liter size (e.g. 3.4L) VIN CODE (e.g. X) RPO (e.g. LQ1) If ALL the information from the vehicle (year, size, VIN Code, RPO) you're working on can be found under the models listed above, then this bulletin applies to that engine. If one or more of the vehicle's information can NOT be found under the models listed above, then this bulletin does NOT apply. This bulletin does not apply to 2004-2007 Saturn VUE models with 3.5L DOHC V6 Engine (VIN 4 RPO L66) or 2005-2008 Cadillac CTS with 2.8L HFV6 Engine (VIN T - RPO LP1). Condition Some customers may comment on external oil leakage. Correction Before replacement of the new design crankshaft rear main oil seal, be sure the PCV system is operating correctly. The new seal described below comes with a protective nylon sleeve already installed in the seal. This sleeve assures that the seal is installed in the correct direction and also protects the seal from getting damaged during installation. Do not remove the protective sleeve from the seal; if removed, the installation tool (EN48108) will not work. A new design crankshaft rear main oil seal and installation tool (EN-48108) has been released. This seal incorporates features that improve high mileage durability. Replace the crankshaft rear main oil seal with the new design rear main oil seal, P/N 12592195, using the following service procedures. Tools Required TOOLS WERE SHIPPED TO YOUR DEALERSHIPS. IF YOU HAVE NOT RECEIVED THEM OR THEY ARE LOST, PLEASE CALL GM SPECIAL SERVICE TOOLS AT 1-800-GM-TOOLS. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Main Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3237 EN-48108 Rear Main Oil Seal Installation Tool This tool has a unique design to allow the technician to easily install the rear main seal squarely to the correct depth and direction. Before proceeding with installation, review the above illustration to become familiar with the components shown in the illustration. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Main Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3238 EN-48672 rear Main Oil Seal Remover Tool This tool has a unique design to allow the technician to easily remove the rear main seal without nicking the crankshaft sealing surface when removing the seal. Before proceeding with removal, review the above illustration to become familiar with the following components: Removal Plate Threaded Adjustment Pins and Jam Nuts Force Screw # 2 Self Drill Screws 38 mm (1.5 in) long 8 needed Extreme Pressure Lubricant Removal Procedure Remove the transmission. Refer to Transmission Replacement in SI or the appropriate Service Manual. Remove the engine flywheel. Refer to Engine Flywheel Replacement in SI or the appropriate Service Manual. Install the removal plate (2) and both threaded adjustment pins and jam nuts (1) into the back of the crankshaft flange and secure the plate with adjustment pins and jam nuts. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Main Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3239 Install # 2 Self Drill Screws 38 mm (1.5 in) long, eight needed, (1) and tighten down flush to the plate. Before installing the force screw, apply a small amount of the Extreme Pressure Lubricant J 23444-A, provided in the tool kit. Install the force screw (1) and back off both jam nuts (2) and continue to turn the force screw (1) into the removal plate to remove the seal from the crankshaft. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Main Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3240 Once the seal is removed from the crankshaft, remove and save all eight screws and discard the old seal. Clean the crankshaft sealing surface with a clean, lint free towel. Inspect the lead-in edge of the crankshaft for burrs or sharp edges that could damage the rear main oil seal. Remove any burrs or sharp edges with crocus cloth or equivalent before proceeding. Installation Procedure Do not remove the protective nylon sleeve from the new rear main seal prior to installation. The EN-48108 is designed to install the rear main seal with the protective sleeve in place. Never apply or use any oil, lubricants or sealing compounds on the crankshaft rear main oil seal. Align the mandrel dowel pin (EN-48108) to the dowel pin hole in the crankshaft. Refer to the above illustration. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Main Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3241 Using a large flat-bladed screwdriver, tighten the two mandrel screws to the crankshaft. Ensure that the mandrel is snug to the crankshaft hub. Refer to the above illustration. Different types (styles) of rear main seals were used in production in different model years, engines and manufacturing facilities. As a result, the NEW style rear main seal that you will be installing may have a different appearance or shape than the one removed. Regardless of what type of seal was removed and what side was facing outside the engine, the new seal must be installed as described. Upon close inspection of the outer lip on the new seal, the words this side out" will be seen. This side of the seal must be facing OUTSIDE the engine when correctly installed. While this may seem backwards, it is correct. In addition, the protective nylon (plastic) sleeve that the seal is mounted on in the package was designed so that the seal can only be installed in the proper direction when using the installation tool described in the following steps. Install the rear main seal (1), with the protective nylon sleeve attached (2), onto the mandrel. The seal, if properly installed, will center on a step that protrudes from the center of the mandrel. As an error proof, seal will fit only one way onto the mandrel. Refer to the above illustration. Before installing the outer drive drum, bearing, washer and the drive nut onto the threaded shaft, apply a small amount of the Extreme Pressure Lubricant J 23444-A, provided in the tool kit. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Main Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3242 Install the outer drive drum onto the mandrel (EN-481 08). Install the bearing, washer and the drive nut onto the threaded shaft. Refer to the above illustration. Using a wrench, turn the drive nut on the mandrel (EN-48108), which will push the seal into the engine block bore. Turn the wrench until the drive drum is snug and flush against the engine block. Refer to the above illustration. Loosen and remove the drive nut, washer, bearing and drive drum. Discard the protective nylon sleeve. Verify that the seal has seated properly. Use a flat-bladed screwdriver to remove the two attachment screws from the mandrel and remove the mandrel from the crankshaft hub. Refer to the above illustration. Install the engine flywheel. Refer to Engine Flywheel Replacement in SI or the appropriate Service Manual. Install the transmission. Refer to Transmission Replacement in SI or the appropriate Service Manual. Inspect for proper fluid levels. Inspect for leaks. Parts Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Main Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3243 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Page 3244 Crankshaft Main Bearing Seal: Service and Repair Removal Procedure 1. Remove the transaxle. Refer to Transmission Replacement in Transmission and Drivetrain. 2. Remove the engine flywheel. Refer to Engine Flywheel Replacement. Important: Do not nick the crankshaft sealing surface when removing the seal. 3. Remove the crankshaft rear oil seal. 3.1. Insert a flat-bladed tool or similar tool through the dust lip at an angle. 3.2. Pry the crankshaft rear oil seal out by moving the handle of the tool towards the end of the crankshaft. 3.3. Repeat as necessary around the crankshaft rear oil seal. Installation Procedure - Tools Required J 34686 Crankshaft Rear Oil Seal Installer 1. Entirely coat the new crankshaft rear oil seal with engine oil. 2. Install the crankshaft rear oil seal. Refer to Crankshaft Rear Oil Seal Installation. 3. Install the engine flywheel. Refer to Engine Flywheel Replacement. 4. Install the transaxle. Refer to Transmission Replacement in Transmission and Drivetrain. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > Customer Interest for Front Crankshaft Seal: > 07-06-01-023 > Dec > 07 > Engine - Oil Leaks From Front Crankshaft Seal Front Crankshaft Seal: Customer Interest Engine - Oil Leaks From Front Crankshaft Seal Bulletin No.: 07-06-01-023 Date: December 05, 2007 TECHNICAL Subject: 60 Degree V6 Engine Oil Leak at Crankshaft Front Oil Seal (Use New Crankshaft Front Oil Seal Installer Tool EN-48869) Models: 1986-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) with 2.8L, 3.1L, 3.4L, 3.5L or 3.9L 60 Degree V6 Engine (VINs D, E, F, J, K, L, M, N, R, S, T, V, W, X, Z, 1, 3, 8, 9, W, R - RPOs LG6, LA1, LNJ, LG8, LL1 or LX9, L82, LL2, LB8, LHO, LG5, LB6, LE2 or LQ1, LH7, LC1, L44, LZ4, LZE, LZ9, LGD, LZ8, LZG) This bulletin does not apply to 2004-2007 Saturn VUE models with 3.5L DOHC V6 Engine (VIN 4 RPO L66) or 2005-2008 Cadillac CTS with 2.8L HFV6 Engine (VIN T - RPO LP1). This bulletin only applies to 60 degree V6 engines. Some of the discontinued 60 degree V6 engine VINs and RPOs may have carried over to other new model year engines and may no longer be a 60 degree V6 engine. So this bulletin may not apply. It is very important to verify that the information shown is correct before using this bulletin. If ALL the information from the vehicle (year, size, VIN Code, RPO) you're working on can be found under the models listed above, then this bulletin applies to that engine. If one or more of the vehicle's information can NOT be found under the models listed above, then this bulletin does NOT apply. Condition Some customers may comment on external oil leakage. Correction Before replacement of the crankshaft front oil seal, be sure the PCV system is operating correctly. Tools Required TOOLS WERE SHIPPED TO YOUR DEALERSHIPS. IF YOU HAVE NOT RECEIVED THEM OR THEY ARE LOST, PLEASE CALL GM SPECIAL SERVICE TOOLS AT 1-800-GM-TOOLS. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > Customer Interest for Front Crankshaft Seal: > 07-06-01-023 > Dec > 07 > Engine - Oil Leaks From Front Crankshaft Seal > Page 3253 The EN-48869 has a unique design to allow the technician to easily install the front crankshaft seal squarely to the correct depth and direction. Before proceeding with installation, review the illustration to become familiar with the tool. Removal Procedure Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement in SI. Use care not to damage the engine front cover or nick the crankshaft. Remove the crankshaft front oil seal (1) using a suitable tool. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > Customer Interest for Front Crankshaft Seal: > 07-06-01-023 > Dec > 07 > Engine - Oil Leaks From Front Crankshaft Seal > Page 3254 Lubricate the inside of the crankshaft front oil seal (1) with clean engine oil. Then install the seal to the installer body (2). Align the oil seal and installer body (1) with the engine front cover and crankshaft. Before installing the force screw, apply a small amount of the Extreme Pressure Lubricant J 23444-A, provided in the tool kit, to the force screw. Install the drive nut (4) onto the threaded force screw shaft (5), washer (3), and bearing (2). Then install to the installer body (1) and tighten the force screw to the crankshaft by hand. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > Customer Interest for Front Crankshaft Seal: > 07-06-01-023 > Dec > 07 > Engine - Oil Leaks From Front Crankshaft Seal > Page 3255 Using a wrench, turn the drive nut on the threaded force screw shaft (2), this will push the seal into the engine front cover. Continue to turn the drive nut (2) with the wrench until the installer body (1) is snug and flush against the engine front cover. Loosen and remove the drive nut from the threaded force screw shaft, washer, bearing, and installer body. Verify that the seal has seated properly, flush against front cover flange (1). Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement in SI. Inspect for proper fluid levels. Inspect for leaks. Parts Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > Customer Interest for Front Crankshaft Seal: > 07-06-01-023 > Dec > 07 > Engine - Oil Leaks From Front Crankshaft Seal > Page 3256 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Crankshaft Seal: > 07-06-01-023 > Dec > 07 > Engine - Oil Leaks From Front Crankshaft Seal Front Crankshaft Seal: All Technical Service Bulletins Engine - Oil Leaks From Front Crankshaft Seal Bulletin No.: 07-06-01-023 Date: December 05, 2007 TECHNICAL Subject: 60 Degree V6 Engine Oil Leak at Crankshaft Front Oil Seal (Use New Crankshaft Front Oil Seal Installer Tool EN-48869) Models: 1986-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) with 2.8L, 3.1L, 3.4L, 3.5L or 3.9L 60 Degree V6 Engine (VINs D, E, F, J, K, L, M, N, R, S, T, V, W, X, Z, 1, 3, 8, 9, W, R - RPOs LG6, LA1, LNJ, LG8, LL1 or LX9, L82, LL2, LB8, LHO, LG5, LB6, LE2 or LQ1, LH7, LC1, L44, LZ4, LZE, LZ9, LGD, LZ8, LZG) This bulletin does not apply to 2004-2007 Saturn VUE models with 3.5L DOHC V6 Engine (VIN 4 RPO L66) or 2005-2008 Cadillac CTS with 2.8L HFV6 Engine (VIN T - RPO LP1). This bulletin only applies to 60 degree V6 engines. Some of the discontinued 60 degree V6 engine VINs and RPOs may have carried over to other new model year engines and may no longer be a 60 degree V6 engine. So this bulletin may not apply. It is very important to verify that the information shown is correct before using this bulletin. If ALL the information from the vehicle (year, size, VIN Code, RPO) you're working on can be found under the models listed above, then this bulletin applies to that engine. If one or more of the vehicle's information can NOT be found under the models listed above, then this bulletin does NOT apply. Condition Some customers may comment on external oil leakage. Correction Before replacement of the crankshaft front oil seal, be sure the PCV system is operating correctly. Tools Required TOOLS WERE SHIPPED TO YOUR DEALERSHIPS. IF YOU HAVE NOT RECEIVED THEM OR THEY ARE LOST, PLEASE CALL GM SPECIAL SERVICE TOOLS AT 1-800-GM-TOOLS. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Crankshaft Seal: > 07-06-01-023 > Dec > 07 > Engine - Oil Leaks From Front Crankshaft Seal > Page 3262 The EN-48869 has a unique design to allow the technician to easily install the front crankshaft seal squarely to the correct depth and direction. Before proceeding with installation, review the illustration to become familiar with the tool. Removal Procedure Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement in SI. Use care not to damage the engine front cover or nick the crankshaft. Remove the crankshaft front oil seal (1) using a suitable tool. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Crankshaft Seal: > 07-06-01-023 > Dec > 07 > Engine - Oil Leaks From Front Crankshaft Seal > Page 3263 Lubricate the inside of the crankshaft front oil seal (1) with clean engine oil. Then install the seal to the installer body (2). Align the oil seal and installer body (1) with the engine front cover and crankshaft. Before installing the force screw, apply a small amount of the Extreme Pressure Lubricant J 23444-A, provided in the tool kit, to the force screw. Install the drive nut (4) onto the threaded force screw shaft (5), washer (3), and bearing (2). Then install to the installer body (1) and tighten the force screw to the crankshaft by hand. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Crankshaft Seal: > 07-06-01-023 > Dec > 07 > Engine - Oil Leaks From Front Crankshaft Seal > Page 3264 Using a wrench, turn the drive nut on the threaded force screw shaft (2), this will push the seal into the engine front cover. Continue to turn the drive nut (2) with the wrench until the installer body (1) is snug and flush against the engine front cover. Loosen and remove the drive nut from the threaded force screw shaft, washer, bearing, and installer body. Verify that the seal has seated properly, flush against front cover flange (1). Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement in SI. Inspect for proper fluid levels. Inspect for leaks. Parts Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Crankshaft Seal: > 07-06-01-023 > Dec > 07 > Engine - Oil Leaks From Front Crankshaft Seal > Page 3265 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > Page 3266 Front Crankshaft Seal: Service and Repair Removal Procedure 1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement. 2. Use a suitable tool in order to pry out the crankshaft front oil seal. Refer to the instructions supplied with the replacement part. 3. Inspect the crankshaft, the crankshaft balancer and the engine front cover for wear and/or damage. Replace or repair the crankshaft, the crankshaft balancer and/or engine front cover as necessary. Installation Procedure - Tools Required J 35468 Crankshaft Front Oil Seal Installer 1. Lubricate the crankshaft front oil seal with engine oil in order to make installation easier. Install the crankshaft front oil seal using the J 35468. Make sure that the crankshaft front oil seal lip faces the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > Page 3267 2. Make sure the crankshaft front oil seal is installed flush to the engine front cover (1). 3. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement. 4. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 03-06-01-010C > Apr > 08 > Engine/Cooling System - Oil or Coolant Leaks Intake Manifold Gasket: Customer Interest Engine/Cooling System - Oil or Coolant Leaks TECHNICAL Bulletin No.: 03-06-01-010C Date: April 08, 2008 Subject: Engine Oil or Coolant Leak (Install New Lower Intake Manifold Gasket) Models: 2000-2003 Buick Century 2002-2003 Buick Rendezvous 1996 Chevrolet Lumina APV 1997-2003 Chevrolet Venture 1999-2001 Chevrolet Lumina 1999-2003 Chevrolet Malibu, Monte Carlo 2000-2003 Chevrolet Impala 1996-2003 Oldsmobile Silhouette 1999 Oldsmobile Cutlass 1999-2003 Oldsmobile Alero 1996-1999 Pontiac Trans Sport 1999-2003 Pontiac Grand Am, Montana 2000-2003 Pontiac Grand Prix 2001-2003 Pontiac Aztek with 3.1L or 3.4L V-6 Engine (VINs J, E - RPOs LG8, LA1) Supercede: This bulletin is being revised to update the Parts Information and add an Important statement. Please discard Corporate Bulletin Number 03-06-01-010B (Section 06 - Engine). Condition Some owners may comment on an apparent oil or coolant leak. Additionally the comments may range from spots on the driveway to having to add fluids. Cause Lower Intake manifold may be leaking allowing coolant oil or both to leak from the engine. Correction Install a new design lower intake manifold gasket. The material used in the gasket has been changed in order to improve the sealing qualities of the gasket. When replacing the gasket the lower intake manifold bolts must also be replaced and torqued in sequence to a specification. Important: The gasket kit part number listed below now includes the new bolts (4 long bolts and 4 short bolts) with the pre-applied threadlocker on them. It is no longer necessary to order the bolts separately when ordering gaskets. Notice: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 03-06-01-010C > Apr > 08 > Engine/Cooling System - Oil or Coolant Leaks > Page 3276 An oil leak may result if the vertical bolts are not tightened before the diagonal bolts. Diagonal bolts may require a crows foot to tighten. Tighten 1. Tighten the vertical lower intake manifold bolts (1) to 7 N.m (62 lb in). 2. Tighten the diagonal lower intake manifold bolts (2) to 7 N.m (62 lb in). 3. Tighten the vertical lower intake manifold bolts (1)to 13 N.m (115 lb in). 4. Tighten the diagonal lower intake manifold bolts (2) to 25 N.m (18 lb ft). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 03-06-01-010C > Apr > 08 > Engine/Cooling System - Oil or Coolant Leaks Intake Manifold Gasket: All Technical Service Bulletins Engine/Cooling System - Oil or Coolant Leaks TECHNICAL Bulletin No.: 03-06-01-010C Date: April 08, 2008 Subject: Engine Oil or Coolant Leak (Install New Lower Intake Manifold Gasket) Models: 2000-2003 Buick Century 2002-2003 Buick Rendezvous 1996 Chevrolet Lumina APV 1997-2003 Chevrolet Venture 1999-2001 Chevrolet Lumina 1999-2003 Chevrolet Malibu, Monte Carlo 2000-2003 Chevrolet Impala 1996-2003 Oldsmobile Silhouette 1999 Oldsmobile Cutlass 1999-2003 Oldsmobile Alero 1996-1999 Pontiac Trans Sport 1999-2003 Pontiac Grand Am, Montana 2000-2003 Pontiac Grand Prix 2001-2003 Pontiac Aztek with 3.1L or 3.4L V-6 Engine (VINs J, E - RPOs LG8, LA1) Supercede: This bulletin is being revised to update the Parts Information and add an Important statement. Please discard Corporate Bulletin Number 03-06-01-010B (Section 06 - Engine). Condition Some owners may comment on an apparent oil or coolant leak. Additionally the comments may range from spots on the driveway to having to add fluids. Cause Lower Intake manifold may be leaking allowing coolant oil or both to leak from the engine. Correction Install a new design lower intake manifold gasket. The material used in the gasket has been changed in order to improve the sealing qualities of the gasket. When replacing the gasket the lower intake manifold bolts must also be replaced and torqued in sequence to a specification. Important: The gasket kit part number listed below now includes the new bolts (4 long bolts and 4 short bolts) with the pre-applied threadlocker on them. It is no longer necessary to order the bolts separately when ordering gaskets. Notice: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 03-06-01-010C > Apr > 08 > Engine/Cooling System - Oil or Coolant Leaks > Page 3282 An oil leak may result if the vertical bolts are not tightened before the diagonal bolts. Diagonal bolts may require a crows foot to tighten. Tighten 1. Tighten the vertical lower intake manifold bolts (1) to 7 N.m (62 lb in). 2. Tighten the diagonal lower intake manifold bolts (2) to 7 N.m (62 lb in). 3. Tighten the vertical lower intake manifold bolts (1)to 13 N.m (115 lb in). 4. Tighten the diagonal lower intake manifold bolts (2) to 25 N.m (18 lb ft). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Valve Stem Oil Seal and Valve Spring Replacement Valve Guide Seal: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement Removal Procedure - Tools Required J 22794 Spark Plug Port Adapter - J 38606 Valve Spring Compressor Important: Before you remove the valve locks, rotate the engine so that the piston in the cylinder you are working on is at (TDC) top dead center. This will eliminate the possibility of the valve accidentally failing inside the cylinder. - Break the spark plug loose, and clean any dirt and debris from the spark plug recess area before removing. 1. Remove the spark plug. Refer to Spark Plug Replacement in Powertrain Management. 2. Install the J22794 into the spark plug port. Apply compressed air in order to hold the valves in place. 3. Remove the rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement. 4. Install the J 38606 on the valve spring. 5. Compress the valve spring with the J 38606. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Valve Stem Oil Seal and Valve Spring Replacement > Page 3287 6. Remove the valve locks. 7. Remove the valve cap. 8. Remove the valve spring. 9. Inspect the valve spring for damage. Replace the spring if it is damaged. 10. Remove the spring seat/valve stem oil seal. Installation Procedure - Tools Required J22794 Spark Plug Port Adapter - J 38606 Valve Spring Compressor 1. Install the valve stem oil seal/spring seat. - Use a suitable driver. - Press over the valve guide boss. 2. Install the valve spring. 3. Install the valve cap. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Valve Stem Oil Seal and Valve Spring Replacement > Page 3288 4. Compress the valve spring with the J 38606. 5. Install the valve locks. If necessary, hold the valve locks in place with grease. 6. Release the valve spring using the J 38606. 7. Make sure that the valve locks are seated. 8. Install the valve rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement. 9. Release the air pressure and remove the J 22794. 10. Install the spark plug. Refer to Spark Plug Replacement in Powertrain Management. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Valve Stem Oil Seal and Valve Spring Replacement > Page 3289 Valve Guide Seal: Service and Repair Additional Information Refer to Engine Service and Repair for additional engine repair information for this component. See: Service and Repair If an internal engine component does not have a separate service procedure at this location, the manufacturer did not provide one. Please refer to "Unit Repair" under Engine/Service and Repair for available service procedures. See: Service and Repair "Unit Repair" typically covers service procedures, machining, cleaning, inspection, and fitting necessary as part of engine overhaul: - Cylinder Boring and Honing - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Camshaft Bearings - Replacement - Connecting Rod and Piston - Disassembly - Cylinder Head - Disassembly - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Oil Pump - Disassembly - Pistons and Rings - Fitting - Thread repair information - Valve and Seat Grinding (Valve Job) - See also "Cylinder Head Assembly" See: Cylinder Head Assembly - Timing Components (Chain, Belt, Gears) service - See also "Timing Components" See: Timing Components Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Specifications Oil Level Sensor: Specifications Oil Level Sensor Bolt 89 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Specifications > Page 3294 Oil Level Sensor: Locations Locations View Front center of the engine oil pan. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Locations Oil Level Sensor For ECM: Locations Front center of the engine oil pan. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Locations > Page 3298 Engine Oil Level Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Engine Oil Pressure Indicator Switch 115 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 3302 Engine Oil Pressure Indicator Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 3306 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Component Locations Oil Pressure Switch (For Fuel Pump): Component Locations Engine Oil Pressure Indicator Switch (LA1) Front of the engine, above the starter. RPO LA1: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Engine Oil Pressure Indicator Switch (L36) Near generator. RPO L36: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Component Locations > Page 3311 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Component Locations > Page 3312 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 3313 Oil Pressure Switch (For Fuel Pump): Description and Operation Engine Oil Pressure Switch The PCM monitors the engine oil pressure switch (1) signal to determine if the engine oil pressure is OK. If the PCM determines that a low oil pressure condition exists, the PCM will communicate the information over the Class II circuit to the P cluster and it will illuminate the indicator lamp or initiate a message. The low oil pressure message may not appear if other messages are being commanded, such as the rear deck lid, driver or passenger doors ajar. Ensure that all doors and compartment lids are completely closed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Camshaft Sprocket - Design Identification Camshaft Gear/Sprocket: Technical Service Bulletins Camshaft Sprocket - Design Identification File In Section: 06 - Engine/Propulsion System Bulletin No.: 00-06-01-004 Date: March, 2000 INFORMATION Subject: Identification of Camshaft Sprocket Design for Service Models: 2000 Buick Century 2000 Chevrolet Impala, Malibu, Monte Carlo, Venture 2000 Oldsmobile Alero, Silhouette 2000 Pontiac Grand Am, Montana With 3.1 L or 3.4 L Engine (VINs J, E - RPOs LGB, LA1) Some dealers may have parts identification concerns regarding the 2000 3.1 L and 3.4 L engines (RPOs LG8, LA1) camshaft and crankshaft timing components. Dealers may have encountered that parts ordered do not fit, or have a different appearance than those the vehicle was originally equipped with. The cause is revised drive sprockets, chain and dampener introduced into vehicle production, replacing previous design components. This occurred during the model year. Important: Previous and revised design components may not be intermixed with each other. Attempting to use a mix of the two types of timing components will result in the inability to assemble and time the vehicle. Reference the following figures and associated pant numbers to clarify which replacement parts should be ordered, depending upon which design the vehicle was equipped with. If it is necessary to replace all components during service, it is recommended to use the revised design components. Parts are currently available from GMSPO. Previous Design Sprocket Identification And Part Numbers Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Camshaft Sprocket - Design Identification > Page 3319 Revised Sprocket Design Revised Sprocket Identification And Part Numbers Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Page 3320 Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt 103 lb. ft. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Balancer Bolt 76 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams Timing Chain: Diagrams Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams > Page 3327 Timing Chain: Service and Repair - Tools Required J 38612 Crankshaft Sprocket Installer 1. Install the crankshaft sprocket using the J 38612. 2. Apply prelube GM P/N 1052365 or the equivalent to the crankshaft sprocket thrust surface. 3. Install the timing chain dampener. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the timing chain dampener bolts. Tighten the timing chain dampener bolt to 21 Nm (15 ft. lbs.). 5. Align the crankshaft timing mark (2) to the timing mark on the bottom of the timing chain dampener (1). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams > Page 3328 6. Hold the camshaft sprocket with the timing chain hanging down and install the timing chain to the crankshaft gear. 7. Align the timing mark on the camshaft gear (4) with the timing mark on top of the timing chain dampener (3). 8. Align the dowel in the camshaft with the dowel hole in the camshaft sprocket. 9. Draw the camshaft sprocket onto the camshaft using the mounting bolt. 10. Coat the crankshaft and camshaft sprocket with engine oil. Tighten the bolt to 140 Nm (103 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Specifications Timing Chain Guide: Specifications Timing Chain Dampener Bolt .............................................................................................................. ............................................................... 15 ft. lbs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Engine Front Cover Bolt Large 41 ft.lb Engine Front Cover Bolt Medium 35 ft.lb Engine Front Cover Bolt Small 15 ft.lb Thermostat Bypass Pipe to Engine Front Cover Bolt 106 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3335 Timing Cover: Service and Repair Removal Procedure 1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 2. Drain the engine coolant from the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 3. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement. 4. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement in Cooling System. 5. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement. 6. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement. 7. Remove the power steering pump with the lines. Reposition the power steering pump. Refer to Power Steering Pump Replacement in Steering and Suspension. 8. Disconnect the thermostat bypass pipe from the engine front cover. Refer to Thermostat Bypass Pipes Replacement in Cooling System. 9. Disconnect the radiator outlet hose from the coolant pump. Refer to Radiator Hose Replacement - Outlet in Cooling System. 10. Remove the coolant pump pulley. Refer to Water Pump Replacement in Cooling System. 11. Remove the lower crankshaft position sensor wiring harness bracket from the engine front cover. 12. Remove the engine front cover bolts (1, 2 and 3). 13. Remove the engine front cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3336 14. Remove the engine front cover gasket. 15. Clean the engine front cover and engine block gasket sealing surfaces. Refer to Engine Front Cover Clean and Inspect. 16. Inspect the engine front cover for damage to the engine front cover, crankshaft front oil seal or the gasket sealing surface. Refer to Engine Front Cover Clean and Inspect. 17. If replacing the engine front cover, remove the drive belt shield. 18. If replacing the engine front cover, remove the crankshaft position sensor from the engine front cover. Refer to Crankshaft Position (CKP) Sensor Replacement (7X CKP Sensor) or Crankshaft Position (CKP) Sensor Replacement (24X CKP Sensor) in Computers and Controls. 19. If replacing the engine front cover, remove the coolant pump from the engine front cover. Refer to Water Pump Replacement in Cooling System. Installation Procedure 1. If removed, install the coolant pump to the engine front cover. Refer to Water Pump Replacement in Cooling System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3337 2. If removed, install the crankshaft position sensor to the engine front cover. Refer to Crankshaft Position (CKP) Sensor Replacement (7X CKP Sensor) or Crankshaft Position (CKP) Sensor Replacement (24X CKP Sensor) in Computers and Controls. Notice: Refer to Fastener Notice in Service Precautions. 3. If removed, install the drive belt shield. Install the drive belt shield bolt. Tighten the drive belt shield bolt to 10 Nm (89 inch lbs.). 4. Install the engine front cover gasket. 5. Install the engine front cover. 6. Install the engine front cover bolts (1, 2 and 3). Refer to Engine Front Cover Installation. 7. Install the lower crankshaft position sensor wiring harness bracket to the engine front cover 8. Install the coolant pump pulley. Refer to Water Pump Replacement in Cooling System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3338 9. Connect the radiator outlet hose to the coolant pump. Refer to Radiator Hose Replacement -Outlet in Cooling System. 10. Connect the thermostat bypass pipe to the engine front cover. Refer to Thermostat Bypass Pipes Replacement in Cooling System. 11. Install the power steering pump with the lines. Refer to Power Steering Pump Replacement in Steering and Suspension. 12. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement. 13. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement. 14. Fill the engine with new engine oil. Refer to Engine Oil and Oil Filter Replacement. 15. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 16. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 17. Perform a CKP system variation learn procedure. Refer to CKP System Variation Learn Procedure in Computers and Controls. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure - Correct Operating Range Fuel Pressure: Technical Service Bulletins Fuel Pressure - Correct Operating Range File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-018 Date: May, 1999 INFORMATION Subject: Correct Fuel Pressure Operating Range Models: 2000 Buick Century 2000 Chevrolet Impala, Lumina, Malibu, Monte Carlo, Venture 2000 Oldsmobile Alero, Silhouette 2000 Pontiac Grand Am, Grand Prix, Montana with 3.1 L or 3.4 L V6 Engine (VINs J, E - RPOs LG8, LA1) All 2000 model year 3.1 L and 3.4 L engines have a revised fuel pressure regulator and Multec II fuel injectors. The fuel system operating pressure is 358-405 kPa (52-59 psi) on these applications. Important: ^ This regulator is NOT interchangeable with past model applications. When replacement is necessary for the above listed applications, use only regulator P/N 17113622. ^ Installing regulators other than the above listed part number in these applications may result in a change in engine performance and/or driveability concerns. Refer to the Engine Controls subsection of the Service Manual for complete diagnostic and repair information on fuel system related concerns. Parts Information Part Number Description 17113622 Fuel Pressure Regulator Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 3344 Fuel Pressure: Specifications Fuel Pressure Fuel Pressure Fuel Pressure 52-59 psi Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis Fuel Pressure: Testing and Inspection Fuel System Diagnosis Diagnostic Chart (Part 1 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 3347 Diagnostic Chart (Part 2 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 3348 Diagnostic Chart (Part 3 Of 3) SYSTEM DESCRIPTION Proper fuel pressure is necessary to maintain efficient engine operation and emission levels, if fuel pressure is not within specifications vehicle driveablity may be affected or emission levels elevated. The fuel system contains the following components: ^ Fuel strainer ^ Modular fuel sender assembly ^ Fuel filter ^ Fuel feed pipes and hoses ^ Fuel pressure regulator ^ Fuel rail ^ Fuel injectors ^ Fuel return pipes and hoses TEST DESCRIPTION The numbers below refer to the step numbers on the diagnostic table. 2. Tests the fuel systems ability to achieve a specific fuel pressure range. It may be necessary to cycle the fuel pump several times to achieve the pressure range. 6. A fuel system that drops more than 5 psi in 10 minutes has a leak in one or more areas. 8. Tests the fuel systems ability to maintain a specific fuel pressure. It may be necessary to cycle the fuel pump several times to achieve the pressure range. 9. Fuel pressure that drops-off during acceleration, cruise, or hard cornering may cause a lean condition. A lean condition can cause a loss of power, surging, or misfire and may be diagnosed using a scan tool. If an extremely lean condition occurs, the oxygen sensors may drop below 500 mV and the fuel injector pulse width will increase. 13. When the engine is at idle, the manifold pressure is low, high vacuum. This low pressure, high vacuum, is applied to the fuel pressure regulator diaphragm, the result is lower fuel pressure. The fuel pressure at idle will vary slightly as the pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in Step 2 with the engine OFF. 14. This test determines if the high fuel pressure is due to a restricted fuel return pipe or fuel pressure regulator. A rich condition may cause a DTC P0132 or DTC P0172 to set. Driveability conditions associated with rich conditions can include hard starting, followed by black smoke, and a Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 3349 strong sulfur smell in the exhaust. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 3350 Fuel Pressure: Testing and Inspection Fuel System Pressure Test Diagnostic Chart (Part 1 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 3351 Diagnostic Chart (Part 2 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 3352 Diagnostic Chart (Part 3 Of 3) SYSTEM DESCRIPTION Proper fuel pressure is necessary to maintain efficient engine operation and emission levels, if fuel pressure is not within specifications vehicle driveablity may be affected or emission levels elevated. The fuel system contains the following components: ^ Fuel strainer ^ Modular fuel sender assembly ^ Fuel filter ^ Fuel feed pipes and hoses ^ Fuel pressure regulator ^ Fuel rail ^ Fuel injectors ^ Fuel return pipes and hoses TEST DESCRIPTION The numbers below refer to the step numbers on the diagnostic table. 2. Tests the fuel systems ability to achieve a specific fuel pressure range. It may be necessary to cycle the fuel pump several times to achieve the pressure range. 6. A fuel system that drops more than 5 psi in 10 minutes has a leak in one or more areas. 8. Tests the fuel systems ability to maintain a specific fuel pressure. It may be necessary to cycle the fuel pump several times to achieve the pressure range. 9. Fuel pressure that drops-off during acceleration, cruise, or hard cornering may cause a lean condition. A lean condition can cause a loss of power, surging, or misfire and may be diagnosed using a scan tool. If an extremely lean condition occurs, the oxygen sensors may drop below 500 mV and the fuel injector pulse width will increase. 13. When the engine is at idle, the manifold pressure is low, high vacuum. This low pressure, high vacuum, is applied to the fuel pressure regulator diaphragm, the result is lower fuel pressure. The fuel pressure at idle will vary slightly as the pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in Step 2 with the engine OFF. 14. This test determines if the high fuel pressure is due to a restricted fuel return pipe or fuel pressure regulator. A rich condition may cause a DTC P0132 or DTC P0172 to set. Driveability conditions associated with rich conditions can include hard starting, followed by black smoke, and a Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 3353 strong sulfur smell in the exhaust. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 3357 Idle Speed: Adjustments The Powertrain Control Module (PCM) controls engine idle speed by adjusting the position of the Idle Air Control (IAC) motor pintle. The IAC is a bi-directional motor driven by two coils. The PCM pulses current to the IAC coils in steps, counts, to extend the IAC pintle into a passage in the throttle body to decrease air flow. The PCM reverses the current pulses to retract the pintle, increasing air flow. This method allows highly accurate control of idle speed and quick response to changes in engine load. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 3367 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 3373 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 3374 Air Filter Element: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the IAT sensor electrical connector. 3. Disconnect the breather tube from the air intake duct. 4. Disconnect the MAF sensor electrical connector. 5. Loosen the air intake duct/MAF sensor hose clamps. 6. Carefully remove the air inlet hose from the throttle body and air cleaner cover. 7. Remove the 2 housing cover retaining clamps. 8, Remove the air cleaner cover (5) and carefully remove the air filter element (6). 9. Inspect the housing cover (5), seal assembly, and air ducting (2) for damage. INSTALLATION PROCEDURE 1. Carefully install the air filter element (6) into the air cleaner assembly (1). 2. Install the housing cover (5) and install the housing cover retaining screws (2). 3. Carefully install the air inlet hose to the throttle body and air cleaner cover. 4. Tighten the air inlet hose clamp. 5. Install the air intake duct/MAF sensor assembly. 6. Tighten the air intake duct/MAF sensor hose clamps. 7. Connect the breather tube to the air intake duct. 8, Connect the MAF sensor electrical connector. 9. Connect the IAT sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair RELIEF PROCEDURE Tools Required ^ J34730-1A Fuel Pressure Gauge ^ J34730-262 Fuel Pressure Gauge Fitting CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery terminal. IMPORTANT: Mount the fuel pressure gauge fitting below the belt to avoid contact with the belt. 2. Install the J 34730-262 fuel pressure gauge fitting adaptor to the fuel pressure connection. 3. Connect fuel pressure gauge J 34730-1A to the fuel gauge pressure fitting. Wrap a shop towel around the fuel pressure connection while connecting the fuel pressure gauge in order to avoid spillage. 4. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the fuel pressure gauge into an approved container. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations > Page 3382 Ignition Cable: Service Precautions NOTE: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations > Page 3383 Ignition Cable: Service and Repair REMOVAL PROCEDURE 1. Turn the ignition switch to the OFF position. 2. Note the position of the spark plug wire retaining clips. Remove the spark plug wire retaining clips from the engine. NOTE: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged. 3. Note the position of the spark plug wire(s). Remove the spark plug wires (2,4,6) from the front spark plugs by twisting the boot 1/2 turn before removing the spark plug boot(s). 4. Note the position of the spark plug wire(s). Remove the spark plug wires (1,3,5) from the rear spark plugs by twisting the boot 1/2 turn before removing the spark plug boot(s). 5. Remove the spark plug wire retaining clips from the rear of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations > Page 3384 6. Remove the spark plug wires from the ignition coils. 7. Remove the spark plug wires from the engine. 8. If replacing the spark plug wires, transfer any of the following: ^ Boot heat shields ^ Spark plug wire conduit ^ Spark plug wire retaining clips INSTALLATION PROCEDURE 1. Position the spark plug wire(s) to the engine. 2. Install the spark plug wires to the ignition coils in the proper position. 3. Install the spark plug wires (1,3,5) to the rear spark plugs. 4. Install the spark plug wire retaining clips from the rear of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations > Page 3385 5. Install the spark plug wire (2,4,6) to the front spark plugs. 6. Install the spark plug wire retaining clips to the front of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug Usage Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Spark Plug Service Precautions Spark Plug: Service Precautions Spark Plug Service Precautions NOTE: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged. NOTE: Observe the following service precautions: ^ Allow the engine to cool before removing the spark plugs. Attempting to remove spark plugs from a hot engine can cause the spark plugs to seize. This can damage the cylinder head threads. ^ Clean the spark plug recess area before removing the spark plug. Failure to do so can result in engine damage due to dirt or foreign material entering the cylinder head, or in contamination of the cylinder head threads. Contaminated threads may prevent proper seating of the new spark plug. ^ Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the vehicle. Installing spark plugs of another type can severely damage the engine. NOTE: ^ It is important to check the gap of all new and reconditioned spark plugs before installation. Pre-set gaps may have changed during handling. Use a round wire feeler gauge to be sure of an accurate check, particularly on used plugs. Installing plugs with the wrong gap can cause poor engine performance and may even damage the engine. ^ Be sure plug threads smoothly into cylinder head and is fully seated. Use a thread chaser if necessary to clean threads in cylinder head. Cross-threading or failing to fully seat spark plug can cause overheating of plug, exhaust blow-by, or thread damage. Follow the recommended torque specifications carefully. Over or under-tightening can also cause severe damage to engine or spark plug. NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Spark Plug Service Precautions > Page 3391 Spark Plug: Service Precautions Platinum Tip Spark Plug Maintenance Information Platinum Tip Spark Plug Maintenance Information for all 95-02 Models Equipped with Platinum Tip Spark Plugs The following information was originally sent to all General Motors dealers as a DCS message on October 14, 1999. Recommendation / Instructions: It has come to our attention that some GM dealers sell a customer service to remove platinum tipped spark plugs and clean the threads at regular intervals to prevent the seizure of the spark plugs in the cylinder heads at high mileage. Platinum tipped spark plugs are designed to operate under normal vehicle operating conditions for up to 100,000 miles (160,000 kms) without periodic maintenance. When no engine performance concerns are present, platinum tipped spark plugs should not be removed for periodic inspection and cleaning of threads, doing so would compromise the spark plugs ability to withstand their corrosive environment. The threaded area, although not sealed, serves as a protective environment against most harmful elements. Removing and cleaning spark plugs will introduce metallic debris and brush scrapings into the thread area which may further the corrosion process. Chromate coated spark plugs should not be wire brushed or handled in any way once they are put in service. Chromium topcoats form a protective oxide on spark plugs that is not effective if scratched. Both coated and uncoated spark plugs will have the best chance of surviving a corrosive environment if they are left in position. Attempts to maintain spark plugs by removing them and cleaning the threads can actually create the corrosive condition that the procedure was intended to prevent. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Page 3392 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ........................................................ AC Type 41-940 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Page 3393 Spark Plug: Description and Operation Worn, cracked or dirty plugs may give satisfactory operation at idling speed, but under operating conditions they frequently fail. Faulty plugs are indicated in a number of ways: poor fuel economy, loss of power and speed, hesitation, shudder, medium throttle intake manifold backfire, hard starting and general poor engine performance. Fouled plugs may be indicated by black carbon deposits. The black deposits are usually the result of slow-speed driving and short runs where sufficient engine operating temperature is seldom reached. Worn pistons, rings, faulty ignition, over-rich fuel mixture or low heat range spark plugs may result in carbon deposits. Excessive gap wear on plugs of low mileage, usually indicates the engine is operating at high speeds or loads that are consistently greater than normal or that a plug which is too hot of a heat range is being used. Electrode wear may also be the result of plug overheating, caused by combustion gases leaking past the threads, due to insufficient torque of the spark plug. Excessively lean fuel mixture will also result in excessive electrode wear. Broken insulators are usually the result of improper installation or carelessness when gapping the plug. Broken upper insulators usually result from a poor fitting wrench or an outside blow. The cracked insulator may not show up right away, but will as soon as oil or moisture penetrates the crack. The crack is usually just below the crimped part of shell and may not be visible. Broken lower insulators usually result from carelessness when gapping and generally are visible. This type of break may result from the plug operating too Hot, which may happen in periods of high-speed operation or under heavy loads. When gapping a spark plug, always make the gap adjustment by bending the ground (side) electrode. Spark plugs with broken insulators should always be replaced. Each spark plug boot covers the spark plug terminal and a portion of the plug insulator. These boots prevent flash-overwhich causes engine misfiring. Do not mistake corona discharge for flash-over or a shorted insulator. Corona is a steady blue light appearing around the insulator, just above the shell crimp. It is the visible evidence of high-tension field and has no effect on ignition performance. Usually it can be dust particles leaving a clear ring on the insulator just above the shell. This ring is sometimes mistakenly regarded as evidence that combustion gases have blown out between shell and insulator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Page 3394 Spark Plug: Testing and Inspection Normal spark plug operation will result in brown to grayish-tan deposits appearing on the portion of the spark plug that projects into the cylinder area. A small amount of red-brown, yellow, and white powdery material may also be present on the insulator tip around the center electrode. These deposits are normal combustion by-products of fuels and lubricating oils with additives. Some electrode wear will also occur. Engines which are not running properly are often referred to as misfiring. Spark plug misfiring can be indicated in a number of ways: ^ Poor fuel economy ^ Power loss ^ Loss of speed ^ Hard starting ^ Poor engine performance Flashover occurs when a damaged spark plug boot, along with dirt and moisture, permits the high voltage charge to short over the insulator to the spark plug shell or the engine. Should misfiring occur before the recommended replacement interval, locate and correct the cause. Carbon fouling of the spark plug is indicated by dry, black carbon (soot) deposits on the portion of the spark plug in the cylinder. Excessive idling or slow speeds under light engine loads can keep the spark plug temperatures so low that these deposits are not burned off. Rich fuel mixtures or poor ignition system output may also be the cause. Oil fouling of the spark plug is indicated by wet oily deposits on the portion of the spark plug in the cylinder, usually with little electrode wear. This may be caused by oil getting past worn piston rings or valve seals. This condition also may occur during break-in of new or newly overhauled engines. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Page 3395 Deposit fouling of the spark plug occurs when the normal red-brown, yellow or white deposits of combustion by-products become sufficient to cause misfiring. In some cases, these deposits may melt and form a shiny glaze on the insulator around the center electrode. If the fouling is found in only one or two cylinders, valve stem clearances or intake valve seals may be allowing excess lubricating oil to enter the cylinder, particularly if the deposits are heavier on the side of the spark plug that was facing the intake valve. Excessive gap means that the airspace between the center and side electrodes at the bottom of the spark plug is too wide for consistent spark plug firing. This may be due to improper gap adjustment or to excessive wear of the electrodes during use. Check of the gap size and compare the gap measurement to that specified for the vehicle. Excessive gap wear can be an indication of continuous operation at high speeds or with high engine loads, causing the spark plug to run too hot. Too small of a gap indicates the plug was damaged at the time of installation. Another possible cause is an excessively lean fuel mixture. Low or high spark plug installation torque or improper seating of the spark plug can result in the spark plug running too hot and cause excessive gap wear. The spark plug and cylinder head seats must be in good contact for proper heat transfer and spark plug cooling. Dirty or damaged threads in the head or on the spark plug can keep the spark plug from seating even though the proper torque is applied. Once the spark plugs are properly seated, tighten the spark plug to the proper torque. Low torque may result in poor contact of seats due to a loose spark plug. Overtightening may cause the spark plug shell to be stretched and also result in poor contact between seats. In extreme cases, exhaust blow-by and damage beyond simple gap wear may occur. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Page 3396 Cracked or broken insulators may be the result of improper installation, damage during spark plug regapping, or heat shock to the insulator material. Upper insulators can be broken when a poorly fitting tool is used during installation or removal, or when the spark plug is hit from the outside. Cracks in the upper insulator may be inside the shell and not visible. Also, the breakage may not cause problems until oil or moisture penetrates the crack later. A broken or cracked lower insulator tip (around the center electrode) can result from damage during regapping or from heat shock (spark plug suddenly operating too hot). Damage during regapping can happen if the gapping tool is pushed against the center electrode or the insulator around it, causing the insulator to crack. When regapping a spark plug, make the adjustment by only bending the side electrode. Do not contact other parts. Heat shock breakage in the lower insulator tip generally occurs during severe engine operating conditions (high-speeds or heavy-loading) and may be caused by over advanced timing or low grade fuels. Heat shock refers to a rapid increase in the tip temperature that causes the insulator material to crack. Spark plugs with less than the recommended amount of service can sometimes be cleaned and regapped, then returned to service. However, if there is any doubt about the serviceability of a spark plug, replace it. Replace spark plugs with cracked or broken insulators. In some cases, such as flashover, the ignition wire may need to be changed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Page 3397 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT Removal Procedure Tools Required J38491 Spark Plug Heat Shield Removal Tool 1. Turn OFF the ignition switch. 2. Remove the spark plug wires from the spark plugs. NOTE: ^ Allow the engine to cool before removing the spark plugs. Attempting to remove the spark plugs from a hot engine may cause the plug threads to seize, causing damage to cylinder head threads. ^ Clean the spark plug recess area before removing the spark plug. Failure to do so could result in engine damage because of dirt or foreign material entering the cylinder head, or by the contamination of the cylinder head threads. The contaminated threads may prevent the proper seating of the new plug. Use a thread chaser to clean the threads of any contamination. 3. Remove the spark plugs from the engine. Installation Procedure NOTE: ^ Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the vehicle. Installing spark plugs of another type can severely damage the engine. ^ Check the gap of all new and reconditioned spark plugs before installation. The pre-set gaps may have changed during handling. Use a round feeler gage to ensure an accurate check. Installing the spark plugs with the wrong gap can cause poor engine performance and may even damage the engine. 1. Measure the spark plug gap on the spark plugs to be installed and correct as necessary. Spark Plug Gap: 0.060 in (1.52 mm) NOTE: ^ Be sure that the spark plug threads smoothly into the cylinder head and the spark plug is fully seated. Use a thread chaser, if necessary, to clean threads in the cylinder head. Cross-threading or failing to fully seat the spark plug can cause overheating of the plug, exhaust blow-by, or thread damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Page 3398 2. Install the spark plugs to the engine. Torque: 15 N.m (11 ft. lb.) 3. Connect the spark plug wires to the spark plugs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The lowest reading should not be less than 70 percent of the highest reading. No cylinder reading should be less than 689 kPa (100 psi). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3402 Compression Check: Testing and Inspection A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the head gasket. Important: Remove the Powertrain Control Module (PCM) and the ignition fuses from the I/P fuse block. 1. Disable the ignition. 2. Disable the fuel systems. 3. Remove the spark plugs from all the cylinders. 4. Remove the air duct from the throttle body. 5. Block the throttle plate in the open position. 6. Measure the engine compression, using the following procedure: 6.1. Firmly install the compression gauge to the spark plug hole. 6.2. Have an assistant crank the engine through at least 4 compression strokes in the testing cylinder. 6.3. Record the readings on the gauge at each stroke. 6.4. Disconnect the gauge. 6.5. Repeat the compression test for each cylinder. 7. Record the compression readings from all of the cylinders. - The lowest reading should not be less than 70 percent of the highest reading. - No cylinder reading should be less than 689 kPa (100 psi). 8. The following list is examples of the possible measurements: - When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each cylinder. - When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal compression, the piston rings may be the cause. - If the compression improves considerably with the addition of three squirts of oil, the piston rings may be the cause. - When the compression is low on the first stroke and does not build up in the following strokes, the valves may be the cause. - The addition of oil does not affect the compression, the valves may be the cause. - When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause. 9. Remove the block from the throttle plate. 10. Install the air duct to the throttle body. 11. Install the spark plugs. 12. Install the Powertrain Control Module (PCM) fuse. 13. Install the ignition fuse to the I/P fuse block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolt 89 in.lb Water Pump Pulley Bolt 18 ft.lb Water Outlet Bolt 18 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3409 Water Pump: Service and Repair Removal Procedure 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Remove the drive belt guard. 3. Loosen the water pump pulley bolts. 4. Remove the drive belt. Refer to Drive Belt Replacement. 5. Remove the water pump pulley bolts. 6. Remove the water pump pulley. 7. Remove the water pump bolts. 8. Remove the water pump (1). 9. Remove the water pump gasket (2). 10. Clean the water pump mating surfaces. Installation Procedure 1. Install the gasket (2). 2. Install the water pump (1). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3410 3. Install the water pump bolts. Tighten the water pump bolts to 10 Nm (89 inch lbs.). 4. Install the water pump pulley. 5. Tighten the water pump pulley bolts. Tighten the water pump pulley bolts to 25 Nm (18 inch lbs.). 6. Install the drive belt. Refer to Drive Belt Replacement. 7. Install the drive belt guard. 8. Fill the cooling system. Refer to Draining and Filling Cooling System. 9. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 3416 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 3417 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 3418 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 3419 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity 11.3 qt (US) Note: Recheck fluid level after filling system. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 3422 Coolant: Fluid Type Specifications Type Goodwrench(R) or Havoline(R) Silicate-Free DEX-COOL(R) Coolant/Water Mixture 50/50 % Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 3423 Coolant: Service and Repair Ethylene glycol/water fill ratios have been established to ensure a minimum of 50 percent ethylene glycol. Ensure that all the engine block drains and air bleeds are utilized. The cooling system capacity for the 3.41L is 10.4 liters (10.9 quarts). The cooling system capacity for the 3.81L is 9.6 liters (10.1 quarts). The quantities listed in the filling procedure include the additional quantity to displace the air remaining in the cooling system after a static refill. Unless the cooling system is completely drained, residual coolant reduces the amount of coolant required to fill the system. Always check the freeze point protection after filling a cooling system. Using the correct fill ratio and the following procedures will ensure a minimum concentration of 50 percent ethylene glycol. Every five years or 240,000 km, (150,000 miles), whichever occurs first, the cooling system should be drained and filled using the following procedure. Caution: As long as there is pressure in the cooling system, the temperature can be considerably higher than the boiling temperature of the solution in the radiator without causing the solution to boil. Removal of the pressure cap while the engine is hot and pressure is high will cause the solution to boil instantaneously -possibly with explosive force - spewing the solution over the engine, fenders and the person removing the cap. Notice: When adding coolant, it is important that you use GM Goodwrench DEX-COOL(R) or HAVOLINE(R) DEX-COOL(R) coolant. If Coolant other than DEX-COOL(R) or HAVOLINE(R) DEX-COOL(R) is added to the system the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months. Draining Procedure Important: This procedure significantly increases the amount of used coolant and diluted hazardous waste. 1. Park the vehicle on a level surface. 2. Remove and clean coolant recovery reservoir. 3. Remove the radiator cap when the engine is cool: 3.1. Slowly rotating the cap counterclockwise to the detent. Do not press down while rotating pressure cap. 3.2. Wait until any residual pressure (indicated by a hissing sound) is relieved. 3.3. After all hissing stops, continue to rotate the cap counterclockwise. Important: Store the used coolant in a used coolant holding tank. Submit the used coolant for recycling. 4. Place a drain pan under vehicle to collect all the drained coolant. Important: For procedures requiring the cooling system to be partially drained, opening the radiator drain valve should provide sufficient draining and no further actions should be necessary. 5. Open the radiator drain valve located at the bottom of the radiator tank. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 3424 6. 3.4L - Open the air bleed vent (1) on the thermostat housing. The air bleed vent should be opened two to three turns. 7. 3.4L - Open the air bleed vent (1) on the thermostat bypass pipe. The air bleed vent should be opened two to three turns. 8. 3.8L - Open the air bleed vent (1) on the thermostat housing. The air bleed vent should be opened two to three turns. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 3425 9. 3.4L - Remove the engine block coolant drain plug from the engine left side. 10. 3.4L - Remove the engine block coolant drain plug from the engine right side. 11. 3.8L - Remove both block drains (knock sensors). Important: Dispose of used coolant in a proper fashion. Never pour used coolant down the drain. Ethylene glycol antifreeze is a very toxic chemical; disposing of it into the sewer system or ground water is both illegal and ecologically unsound! 12. Allow the coolant to drain completely. Filling Procedure Notice: DO NOT use cooling system seal tabs (or similar compounds) unless otherwise instructed. The use of cooling system seal tabs (or similar compounds) may restrict coolant flow through the passages of the cooling system or the engine components. Restricted coolant flow may cause engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 3426 overheating and/or damage to the cooling system or the engine components/assembly. 1. Close the radiator drain valve. 2. 3.8L - Install both block drains (knock sensors). 3. 3.4L - Install the engine block coolant drain plug to the engine right side. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 3427 4. 3.4L - Install the engine block coolant drain plug to the engine left side. 5. Remove the coolant recovery reservoir and empty. Flush the reservoir with clean water. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement. Important: When filling the cooling system, add GM approved Ethylene Glycol Coolant DEX-COOL GM P/N 12346290. - If the cooling system is being refilled ONLY (no flush), a 50 percent ethylene glycol and 50 percent clean drinkable water mixture should be used to fill the system. Fill the system until the level of the 50/50 mixture has reached the base of the radiator neck. Wait two minutes. Check the level of the coolant mixture. Add a 50/50 ethylene glycol/water mixture as necessary to restore the coolant mixture level to the base of the radiator neck. 6. Slowly fill the cooling system through the radiator neck using the following procedure: 6.1. If the coolant system has been flushed first add 100 percent ethylene glycol: - 3.4L - 5.2 L (5.45 qt.) - 3.8L - 4.8 L (5.05 qt.) 6.2. Slowly add clean drinkable water to the system until the level of the coolant mixture has reached the base of the radiator neck. 6.3. Wait for two minutes. Check the level of the coolant mixture. Add clean drinkable water if necessary to restore the coolant mixture level to the base of the radiator neck. 7. Install the radiator cap making certain the arrows line up with the overflow tube. 8. 3.8L - Close the air bleed valve (1) on the thermostat housing. Important: DO NOT over-torque the air bleed valve. The air bleed valve is made out of brass. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 3428 9. 3.4L - Close the air bleed valve (1) on the thermostat bypass pipe. 10. 3.4L - Close the air bleed valve (1) on the thermostat housing. 11. Fill the coolant recovery reservoir to the COLD mark with of a 50/50 mixture of ethylene glycol and clean drinkable water. Notice: The Low Coolant warning/indicator lamp may come on after this procedure. If after operating the vehicle so that the engine heats up and cools down three times, the Low Coolant warning/indicator lamp does not go out, or fails to come on at the ignition check, and the coolant is above the full cold mark in the reservoir, refer to Low Coolant Warning/indicator Lamp in Instrument Panel, Gauges and Warning Indicators. If at any time the Temperature warning/indicator lamp comes on, immediate action is required. Turn OFF the engine and allow the vehicle to cool. Do not remove the coolant recovery reservoir cap at this time. 12. Inspect the freeze protection of the engine coolant after the engine heats up and cools down three times using a refractometer or a thermohydrometer to ensure proper freeze -37° C (-34° F) protection. Obtain the coolant mixture for the inspection from the base of the radiator neck, NOT from the coolant recovery reservoir. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications Coolant Drain Plug 14 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Drain Plug, Cylinder Block > Component Information > Specifications > Page 3432 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Coolant Filler Neck: > 00-06-02-001 > Jan > 00 > Engine Running Hot And/Or Loss of Coolant Coolant Filler Neck: Customer Interest Engine - Running Hot And/Or Loss of Coolant Bulletin No.: 00-06-02-001 File In Section: 06 Engine/Propulsion System Date: January, 2000 Subject: Engine Running Hot, Overheating and/or Loss of Coolant (Polish Radiator Filler Neck and Replace Radiator Cap) Models: 1999-2000 Passenger Cars and Trucks with Composite Radiator End Tank Condition Some customers may comment on one or more of the following conditions: ^ Engine running hot ^ Engine overheating, and/or ^ Loss of coolant/low coolant message Cause The radiator filler neck may have an imperfection in the sealing surface. Correction Important: DO NOT REPLACE THE RADIATOR. Using a piece of 400 grit wet/dry sandpaper backed with a flat piece of wood, polish the filler neck sealing surface using a circular motion. Replace the radiator pressure cap with a cap of the same part number as shown in the GM Service Parts Catalog. Warranty Information For vehicles repaired under warranty, use: Labor Labor Operation Description Time J3020 Cap, Radiator Filler - Replace 0.2 hr Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Filler Neck: > 00-06-02-001 > Jan > 00 > Engine - Running Hot And/Or Loss of Coolant Coolant Filler Neck: All Technical Service Bulletins Engine - Running Hot And/Or Loss of Coolant Bulletin No.: 00-06-02-001 File In Section: 06 Engine/Propulsion System Date: January, 2000 Subject: Engine Running Hot, Overheating and/or Loss of Coolant (Polish Radiator Filler Neck and Replace Radiator Cap) Models: 1999-2000 Passenger Cars and Trucks with Composite Radiator End Tank Condition Some customers may comment on one or more of the following conditions: ^ Engine running hot ^ Engine overheating, and/or ^ Loss of coolant/low coolant message Cause The radiator filler neck may have an imperfection in the sealing surface. Correction Important: DO NOT REPLACE THE RADIATOR. Using a piece of 400 grit wet/dry sandpaper backed with a flat piece of wood, polish the filler neck sealing surface using a circular motion. Replace the radiator pressure cap with a cap of the same part number as shown in the GM Service Parts Catalog. Warranty Information For vehicles repaired under warranty, use: Labor Labor Operation Description Time J3020 Cap, Radiator Filler - Replace 0.2 hr Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Customer Interest for Coolant Level Sensor: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON Coolant Level Sensor: Customer Interest Instruments - Low Coolant Indicator Always ON Bulletin No.: 04-06-02-007 Date: August 11, 2004 TECHNICAL Subject: Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination) Models: 2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue Condition Some customers may comment that the low engine coolant level indicator is always illuminated. Cause The cause of this condition may be due to engine oil contaminating the coolant. Possible sources of oil contamination are internal engine leaks, improper service procedures, or the addition of some types of anti-leak additives to the cooling system. Once in the coolant, the oil leaves deposits on the level sensor creating an insulating film. This film results in a false activation of the coolant level indicator. Correction Diagnose low coolant level system operation and check the sensor for oil contamination using the procedure listed below. Important: No coolant supplements should be used in GM cooling systems, other than what is approved and recommended by GM. The use of "aftermarket" over-the-counter sealing and cooling supplements may affect the operation of the low coolant level sensor. Discoloration of the coolant recovery bottle is normal and does not necessarily indicate that coolant contamination is present. Flush cooling system only when instructed by this bulletin. 1. Verify that the coolant is at proper level in the radiator and the coolant recovery bottle. If the coolant is low, add proper amount of 50/50 water and DEX-COOL(R) mixture. If the low coolant light operates properly, diagnose the cooling system for loss of coolant as outlined in SI. DO NOT proceed further with this bulletin. 2. Remove the low coolant level sensor. Refer to Coolant Level Module Replacement in the Engine Cooling sub-section. 3. With the key on, the engine off and the coolant level sensor disconnected from the vehicle wiring harness, observe the low coolant light: ^ Light is on - Chassis wiring or instrument cluster concern. Follow the appropriate diagnostic information in SI. ^ Light is out - Proceed to Step 4. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Customer Interest for Coolant Level Sensor: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON > Page 3454 4. With the key off, connect the coolant level sensor into the vehicle's wiring harness. Connect a ground wire (1) to the battery negative terminal. Using a sharp probe (3) attached to the ground wire, ground the coolant sensor probe (2) as shown in the illustration. Make sure a good contact is made. With the key on and the engine off, observe the low coolant light for at least 15 seconds. ^ Light is on - Replace the low coolant sensor and re-check system operation. ^ Light is out - Proceed to Step 5. 5. Using a small wire brush or emery cloth, polish the low coolant level sensor probe to remove any film or oxidation. The probe should be a bright brass color when finished. Use Brake Parts Cleaner to flush removed deposits from the low coolant sensor probe. Re-install the low coolant sensor into the vehicle and proceed to Step 6. 6. Flush the cooling system and install new DEX-COOL(R) mixture as outlined in the SI. Check the vehicle's warranty history to determine if any engine gasket had recently been changed. If there has not been a recent gasket replacement, locate and repair the source of the engine oil contamination. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Customer Interest for Coolant Level Sensor: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON > Page 3455 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Level Sensor: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON Coolant Level Sensor: All Technical Service Bulletins Instruments - Low Coolant Indicator Always ON Bulletin No.: 04-06-02-007 Date: August 11, 2004 TECHNICAL Subject: Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination) Models: 2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue Condition Some customers may comment that the low engine coolant level indicator is always illuminated. Cause The cause of this condition may be due to engine oil contaminating the coolant. Possible sources of oil contamination are internal engine leaks, improper service procedures, or the addition of some types of anti-leak additives to the cooling system. Once in the coolant, the oil leaves deposits on the level sensor creating an insulating film. This film results in a false activation of the coolant level indicator. Correction Diagnose low coolant level system operation and check the sensor for oil contamination using the procedure listed below. Important: No coolant supplements should be used in GM cooling systems, other than what is approved and recommended by GM. The use of "aftermarket" over-the-counter sealing and cooling supplements may affect the operation of the low coolant level sensor. Discoloration of the coolant recovery bottle is normal and does not necessarily indicate that coolant contamination is present. Flush cooling system only when instructed by this bulletin. 1. Verify that the coolant is at proper level in the radiator and the coolant recovery bottle. If the coolant is low, add proper amount of 50/50 water and DEX-COOL(R) mixture. If the low coolant light operates properly, diagnose the cooling system for loss of coolant as outlined in SI. DO NOT proceed further with this bulletin. 2. Remove the low coolant level sensor. Refer to Coolant Level Module Replacement in the Engine Cooling sub-section. 3. With the key on, the engine off and the coolant level sensor disconnected from the vehicle wiring harness, observe the low coolant light: ^ Light is on - Chassis wiring or instrument cluster concern. Follow the appropriate diagnostic information in SI. ^ Light is out - Proceed to Step 4. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Level Sensor: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON > Page 3461 4. With the key off, connect the coolant level sensor into the vehicle's wiring harness. Connect a ground wire (1) to the battery negative terminal. Using a sharp probe (3) attached to the ground wire, ground the coolant sensor probe (2) as shown in the illustration. Make sure a good contact is made. With the key on and the engine off, observe the low coolant light for at least 15 seconds. ^ Light is on - Replace the low coolant sensor and re-check system operation. ^ Light is out - Proceed to Step 5. 5. Using a small wire brush or emery cloth, polish the low coolant level sensor probe to remove any film or oxidation. The probe should be a bright brass color when finished. Use Brake Parts Cleaner to flush removed deposits from the low coolant sensor probe. Re-install the low coolant sensor into the vehicle and proceed to Step 6. 6. Flush the cooling system and install new DEX-COOL(R) mixture as outlined in the SI. Check the vehicle's warranty history to determine if any engine gasket had recently been changed. If there has not been a recent gasket replacement, locate and repair the source of the engine oil contamination. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Level Sensor: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON > Page 3462 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Throttle Body Heater Hose Replacement - Inlet Coolant Line/Hose: Service and Repair Throttle Body Heater Hose Replacement - Inlet Removal Procedure 1. Carefully disconnect the throttle body air inlet duct. 2. Drain the cooling system. Refer to Draining and Filling Cooling System. 3. Disconnect the throttle body inlet hose clamp and the hose (3) from the coolant pipe. 4. Disconnect the throttle body inlet hose (3) from the throttle body. 5. Remove the throttle body inlet hose (3). Installation Procedure 1. Install the throttle body inlet hose (3). 2. Connect the throttle body inlet hose and the clamp (3) to the throttle body. 3. Connect the throttle body inlet hose and the clamp (3) to the coolant pipe. 4. Install the throttle body air inlet duct. 5. Fill the cooling system. Refer to Draining and Filling Cooling System. 6. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Throttle Body Heater Hose Replacement - Inlet > Page 3467 Coolant Line/Hose: Service and Repair Throttle Body Heater Hose Replacement - Outlet Removal Procedure 1. Carefully disconnect the throttle body air inlet duct. 2. Drain the cooling system. Refer to Draining and Filling Cooling System. 3. Disconnect the throttle body outlet hose clamp and the hose (4) from the coolant pipe. 4. Disconnect the throttle body outlet hose clamp and the hose (4) from the throttle body. 5. Remove the throttle body outlet hose (4). Installation Procedure 1. Install the throttle body outlet hose (4). 2. Connect the throttle body outlet hose and the clamp (4) to the throttle body. 3. Connect the throttle body outlet hose and the clamp (4) to the coolant pipe. 4. Install the throttle body air inlet duct. 5. Fill the cooling system. Refer to Draining and Filling Cooling System. 6. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications Coolant Reservoir: Specifications Coolant Recovery Reservoir Mounting Nut ......................................................................................................................................................... 29 inch lbs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 3471 Coolant Reservoir: Service and Repair Removal Procedure 1. Remove the reservoir hose clamp and the hose (1) from the radiator overflow neck fitting. 2. Remove the coolant recovery reservoir nuts (2) from the shock tower studs. 3. Remove the coolant recovery reservoir (3) from the lower retainer and the shock tower studs. 4. Drain the coolant recovery reservoir. Refer to Draining and Filling Cooling System. Installation Procedure 1. Install the coolant recovery reservoir (3) onto the lower retainer and the shock tower studs. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the coolant recovery reservoir nuts (2) to the shock tower studs. Tighten the coolant recovery reservoir nuts to 3.3 Nm (29 inch lbs.). 3. Lubricate the reservoir hose with clean water. Route the hose to the radiator overflow neck fitting. 4. Install the reservoir hose and clamp (1), with the clamp tabs at the 11 0' CLOCK position, to the radiator overflow fitting on the radiator filler neck. The hose end must be flush against the radiator filler neck. Seat the clamp squarely between the radiator filler neck and the flared end of the fitting. 5. Add coolant to the coolant recovery reservoir. Refer to Draining and Filling Cooling System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Engine Cooling Fan, LH Radiator Cooling Fan Motor: Locations Engine Cooling Fan, LH Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Engine Cooling Fan, LH > Page 3477 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Engine Cooling Fan, LH > Page 3478 Radiator Cooling Fan Motor: Locations Engine Cooling Fan, RH Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Engine Cooling Fan, LH > Page 3479 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3482 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3483 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3484 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3485 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3486 Radiator Cooling Fan Motor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3487 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3488 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3489 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3490 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3491 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3492 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3493 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3494 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3495 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3496 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3497 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3498 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3499 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3500 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3501 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3502 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3503 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3504 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3505 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3506 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3507 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3508 Cooling Fan Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations The Coolant Fan Relays are located in the bottom underhood accessory junction block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor Relay: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3514 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3515 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3516 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3517 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3518 Radiator Cooling Fan Motor Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3519 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3520 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3521 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3522 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3523 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3524 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3525 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3526 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3527 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3528 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3529 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3530 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3531 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3532 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3533 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3534 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3535 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3536 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3537 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3538 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3539 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3540 Cooling Fan Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine Compartment Fan > Component Information > Service and Repair Engine Compartment Fan: Service and Repair Removal Procedure Caution: An electric fan under the hood can start up even when the engine is not running and can injure you. Keep hands, clothing and tools away from any underhood electric fan. - To help avoid personal injury or damage to the vehicle, a bent, cracked, or damaged fan blade or housing should always be replaced. Important: If abnormal noise or vibration is felt from the engine compartment, inspect and clean any foreign material from the cooling fan blades. 1. Turn the ignition off. 2. Remove the cooling fans with the cooling fan shroud. Refer to Fan Shroud Replacement. 3. Firmly grasp the cooling fan. Turn the drive plate nut in order to disengage the fan retainers. 4. Remove the cooling fan. Installation Procedure 1. Install the cooling fan. 2. Firmly grasp the cooling fan. Turn the drive plate nut in order to engage the fan retainers. 3. Install the cooling fans with the cooling fan shroud. Refer to Fan Shroud Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor 23 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3548 Coolant Temperature Sensor/Switch (For Computer): Locations LH side, top of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3551 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3552 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3553 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3554 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3555 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3556 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3557 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3558 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3559 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3560 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3561 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3562 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3563 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3564 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3565 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3566 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3567 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3568 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3569 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3570 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3571 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3572 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3573 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3574 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3575 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3576 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3577 Engine Coolant Temperature (ECT) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3578 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3579 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The engine coolant temperature sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance (100,000 ohms at -40°C/-40°F) while high temperature causes low resistance (70 ohms at 130° C/266° F). The PCM supplies a 5.0 volt signal to the engine coolant temperature sensor through a resistor in the PCM and measures the voltage. The voltage will be high when the engine is cold, and low when the engine is hot. By measuring the voltage, the PCM calculates the engine coolant temperature. Engine coolant temperature affects most systems the PCM controls. The scan tool displays engine coolant temperature in degrees. After engine startup, the temperature should rise steadily to about 90°C (194°F) then stabilize when thermostat opens. If the engine has not been run for several hours (overnight), the engine coolant temperature and intake air temperature displays should be close to each other. A hard fault in the engine coolant sensor circuit should set DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage, or DTC P0118 Engine Coolant Temperature (ECT) Sensor Circuit High Voltage, an intermittent fault should set a DTC P1114 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent Low Voltage, or DTC P1115 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent High Voltage. The DTC Diagnostic Aids also contains a chart to test for sensor resistance values relative to temperature. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3580 The ECT sensor (3) also contains another circuit which is used to operate the engine coolant temperature gauge located in the instrument panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3581 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Relieve coolant pressure. 3. Disconnect the ECT sensor electrical connector. 4. Using a deep well socket and extension, remove the sensor. INSTALLATION PROCEDURE 1. Coat the engine coolant temperature sensor threads with sealer P/N 9985253 or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the sensor in the engine. Tighten Tighten the sensor to 23 N.m (17 lb ft). 3. Connect the ECT sensor electrical connector. 4. Start the engine. 5. Inspect for leaks. 6. Inspect the coolant level. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications Fan Shroud: Specifications Cooling Fan Shroud Bolt 89 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications > Page 3585 Fan Shroud: Service and Repair 1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure. 2. Partially drain the cooling system. Refer to Draining and Filling Cooling System. Important: To prevent shearing of the rubber bushings, loosen the bolts on the engine struts before swinging the struts. 3. Remove the engine strut brace bolts from the upper tie bar and rotate the struts and the braces rearward. Refer to Engine Mount Strut Bracket Replacement (Right Lower) or Engine Mount Strut Bracket Replacement (Right Upper) or Engine Mount Strut Bracket Replacement (Left) or Engine Mount Strut Bracket Replacement (Upper Radiator Support). 4. Remove the front fender upper diagonal brace. Refer to Brace Replacement - Front Fender Upper Diagonal (Impala) or Brace Replacement -Front Fender Upper Diagonal (Monte Carlo) in Body and Frame. 5. Carefully disconnect the throttle body air inlet and adjust the air cleaner assembly for access. 6. Disconnect the radiator inlet hose from the radiator. 7. Disengage the cooling fan shroud retainers. 8. Remove the cooling fan shroud bolts. 9. Disconnect the transmission oil cooler lines from the retainers at the bottom of the cooling fan shroud. 10. Disengage the cooling fan shroud clip from the top of the radiator. 11. Reposition the cooling fan shroud for access. 12. Disconnect the cooling fan shroud electrical connector. 13. Remove the cooling fan shroud. Installation Procedure 1. Connect the cooling fan shroud electrical connector. 2. Install the cooling fan shroud. 3. Install the cooling fan shroud clip to the top of the radiator. Apply pressure in order to completely engage the clip onto the radiator. 4. Connect the transmission oil cooler lines to the retainers at the bottom of the cooling fan shroud. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the cooling fan shroud bolts. Tighten the cooling fan shroud bolts to 10 Nm (89 inch lbs.). 6. Install the cooling fan shroud retainers. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications > Page 3586 7. Connect the radiator inlet hose to the radiator. 8. Install the air cleaner assembly and carefully connect the throttle body air inlet duct. 9. Install the front fender upper diagonal brace. Refer to Brace Replacement - Front Fender Upper Diagonal (impala) or Brace Replacement -Front Fender Upper Diagonal (Monte Carlo) in Body and Frame. 10. Rotate the struts and the braces forward to the proper position. Install the engine strut brace bolts to the upper tie bar. Refer to Engine Mount Strut Bracket Replacement (Right Lower) or Engine Mount Strut Bracket Replacement (Right Upper) or Engine Mount Strut Bracket Replacement (Left) or Engine Mount Strut Bracket Replacement (Upper Radiator Support). 11. Fill the cooling system. Refer to Draining and Filling Cooling System. 12. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure. 13. Inspect for proper operation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 3591 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 3592 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3593 Heater Core: Specifications Heater Core Line Clamp Screw 1.5 Nm Heater Core Mounting Clip Screw 1.5 Nm Heater Core Cover Screws 1.5 Nm Heater Core Outlet Cover Screws 1.5 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3594 Heater Core: Description and Operation The heater core is the main component of the heater system. The heater core is located inside of the heater and evaporator module. Engine coolant is pumped into the heater core from the engine whenever the engine is operating. The heater core fins transfers the heat from the engine coolant to the air passing over the heater core. The heater core has specific inlet and outlet tubes. The placement of the heater hoses should be noted prior to servicing the heater core or the heater hoses. The temperature control is linked to the temperature valve by a flexible control cable. When you rotate temperature control counterclockwise to the full COLD position, the temperature valve is held snugly against the air entrance to the heater core. The following actions occur: ^ All of the airflow from the evaporator bypasses the heater core. ^ No heat transfer occurs. When you turn the temperature control away from the full COLD position, the temperature valve begins to direct air to the heater core. This action allows air to flow through the heater core. The farther the temperature control is rotated clockwise, the more the temperature valve directs air through the heater core. The air discharge is warmer when most of the airflow is heated in this manner. The air discharge is warmer because the heated and unheated air flows join and mix together thoroughly beyond the heater core. When you rotate the temperature lever clockwise to the full HOT position, the temperature valve blocks off the passage that allows air to bypass the heater core. This action causes passage of the airflow through the heater core. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3595 Heater Core: Service and Repair HEATER CORE REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner and duct assembly. 2. Remove the fuel injector sight shield if equipped with 3.8L. 3. Drain the coolant. Refer to Draining and Filling Cooling System in Engine Cooling. 4. Disconnect the heater hoses at the heater core. 5. Remove the LH and RH instrument panel insulators. 6. Remove the lower the floor console, if equipped. 7. Remove the bolts and position the HVAC wiring harness bracket aside. IMPORTANT: Position the heater outlet cover downward and rearward in order to disconnect the cover from the rear area floor duct assembly. 8. Remove the heater outlet cover screws. 9. Remove the heater outlet cover. 10. Remove the heater core cover screws. 11. Remove the heater core cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3596 12. Remove and discard the seals (1,2,3) from the heater core cover. 13. Remove and discard the heater core outer seal (5) from the heater core. 14. Remove the heater core pipe retainer clamp screw (2). 15. Remove the heater core line clamp screw (1). 16. Remove the heater core retaining clamp. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3597 17. Remove the heater core from the HVAC lower case. 18. Remove the heater core tube support bracket (clamp). 19. Remove and discard the heater core lower seal (4) from the HVAC case. 20. Remove and discard the heater core center seal (3) from the HVAC case. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3598 21. Remove and discard the heater core upper seal (2) from the HVAC lower case. 22. Remove and discard the heater core side seals (1) from the HVAC lower case. INSTALLATION PROCEDURE 1. Install the heater core side seals (1) to the HVAC lower case. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3599 2. Install the heater core upper seal (2) to the HVAC lower case. 3. Install the heater core center seal (3) to the HVAC case. 4. Install the heater core lower seal (4) to the HVAC case. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3600 5. Install the heater core tube support bracket (clamp). 6. Install the heater core from the HVAC lower case. NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the heater core line clamp screw (2). Tighten Tighten the heater core line clamp screw to 1.5 N.m (13 lb in). 8. Install the heater core mounting clip with a screw (1). Tighten Tighten the heater core mounting clip screw to 1.5 N.m (13 lb in) 9. Install heater core outer seal (5) to the heater core. 10. Install new seals (1,2,3) to the heater core cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3601 11. Install the heater core cover. 12. Install the heater core cover screws. Tighten Tighten the heater core cover screws to 1.5 N.m (13 lb in). 13. Install the heater core outlet cover. 14. Install the heater core outlet cover screws. Tighten Tighten the heater core outlet cover screws to 1.5 N.m (13 lb in). 15. Install the HVAC wiring harness bracket. Install the HVAC wiring harness bracket bolts. Tighten Tighten the HVAC wiring harness bracket bolts to 10 N.m (89 lb in). 16. Install the lower the floor console, if equipped. 17. Install the LH and RH instrument panel insulators. 18. Connect the heater hoses at the heater core. 19. Refill the coolant. Refer to Draining and Filling Cooling System in Engine Cooling. 20. Install the fuel injector sight shield if equipped with 3.8L. 21. Install the air cleaner and duct assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Specifications Heater Hose: Specifications Heater Inlet Pipe Nut 7 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Handling of Refrigerant Lines and Fittings Heater Hose: Service and Repair Handling of Refrigerant Lines and Fittings ^ Ensure that the metal lines do not exhibit the following conditions. This will prevent the loss of system capacity due to line restriction: Dents - kinks ^ Do not bend the flexible hose line to a radius of less that 4 times the diameter of the hose. ^ Do not allow the flexible hose line to come within a distance of 63.5 mm (2 1/2 in) of the exhaust manifold. ^ Inspect the flexible hose lines regularly. Replace the flexible hose line with new hose if one of the following conditions exist: Leaks - Brittleness - Deterioration ^ Before disconnecting any fitting in the refrigeration system, discharge all of the Refrigerant-134a. ^ Once you open a refrigerant line to the atmosphere, cap or tape the line immediately. This will prevent any of the following items from entering the line: Moisture - Dirt ^ Use the proper wrenches when you make connections on the O-ring fittings. Back-up the opposing fitting with a wrench in order to prevent distortion of the following areas: The connecting lines - The components ^ Tighten all of the tubing connections to the specified torque. ^ Too much or too little torque may result in the following conditions: Loose joints - Deformed joint parts - Refrigerant leakage - An inoperative A/C system ^ Ensure that the O-rings and the seats are in perfect condition. A burr or a piece of dirt may cause a refrigerant leak. ^ Install new O-rings that you have lubricated with the mineral base 525 viscosity refrigerant oil. Do not use Polyalkylene Glycol (PAG) synthetic oil. Do not wipe the threads with a cloth. ^ Keep PAG synthetic refrigerant oil off fitting threads. Long term contact of PAG synthetic oil on threads may cause future disassembly difficulties. Flush threads of fitting with mineral base 525 viscosity refrigerant oil. Do not use PAG synthetic oil. Do not wipe threads with a cloth. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Handling of Refrigerant Lines and Fittings > Page 3607 Heater Hose: Service and Repair Heater Hoses Replacement REMOVAL PROCEDURE Tools Required J 38185 Hose Clamp Pliers 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling. 2. Use J 38185 in order to position aside the heater hose inlet and/or outlet clamp. 3. Disconnect the heater inlet hose and/or the outlet hose from the inlet and/or outlet pipe. 4. Use J 38185 in order to position aside the heater core inlet and/or outlet hose clamp. 5. Disconnect the heater inlet hose and/or the outlet hose from the heater core. 6. Remove the heater inlet hose and/or the outlet hose. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Handling of Refrigerant Lines and Fittings > Page 3608 1. Install the heater inlet hose and/or outlet hose. 2. Connect the heater inlet hose and/or the outlet hose to the heater core. IMPORTANT: Position heater core hose clamps in the indicated location. 3. Use J 38185 in order to secure the heater core hose inlet and/or outlet clamp. 4. Connect the heater inlet hose and/or the outlet hose to the inlet and/or outlet pipe. 5. Use J 38185 in order to secure the heater hose inlet and/or outlet clamp. 6. Refill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Handling of Refrigerant Lines and Fittings > Page 3609 Heater Hose: Service and Repair Heater Pipe Replacement - Inlet TOOLS REQUIRED J 38185 Hose Clamp Pliers 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling. 2. Remove the air cleaner and duct assembly. 3. Disconnect the inlet hose (3) from the inlet pipe. 4. Use J 38185 in order to position aside the heater hose inlet clamp. 5. Remove the inlet pipe mounting nut. 6. Remove the inlet pipe. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Handling of Refrigerant Lines and Fittings > Page 3610 1. Install the inlet pipe. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the inlet pipe mounting nut. Tighten Tighten the heater inlet pipe nut to 7 N.m (62 lb in). 3. Connect the inlet hose (3) to the inlet pipe. 4. Use J 38185 in order to position the heater hose inlet clamp. 5. Install the air cleaner and duct assembly. 6. Refill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair Radiator Drain Plug: Service and Repair Removal Procedure 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Remove the radiator drain plug and seal. The seal usually comes out attached to the plug. 3. Remove the body of the drain plug. Use your fingers or needlenose pliers to disengage the locking tangs from the side tank. 4. Clean the drain and the drain plug. Installation Procedure 1. Install the seal on the drain plug stem. 2. Install the drain plug. Make sure that the body is fully seated in the side tank and that the locking tangs are engaged. 3. Fill the cooling system. Refer to Draining and Filling Cooling System. 4. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cap: > 00-06-02-001 > Jan > 00 > Engine - Running Hot And/Or Loss of Coolant Radiator Cap: Customer Interest Engine - Running Hot And/Or Loss of Coolant Bulletin No.: 00-06-02-001 File In Section: 06 Engine/Propulsion System Date: January, 2000 Subject: Engine Running Hot, Overheating and/or Loss of Coolant (Polish Radiator Filler Neck and Replace Radiator Cap) Models: 1999-2000 Passenger Cars and Trucks with Composite Radiator End Tank Condition Some customers may comment on one or more of the following conditions: ^ Engine running hot ^ Engine overheating, and/or ^ Loss of coolant/low coolant message Cause The radiator filler neck may have an imperfection in the sealing surface. Correction Important: DO NOT REPLACE THE RADIATOR. Using a piece of 400 grit wet/dry sandpaper backed with a flat piece of wood, polish the filler neck sealing surface using a circular motion. Replace the radiator pressure cap with a cap of the same part number as shown in the GM Service Parts Catalog. Warranty Information For vehicles repaired under warranty, use: Labor Labor Operation Description Time J3020 Cap, Radiator Filler - Replace 0.2 hr Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cap: > 00-06-02-001 > Jan > 00 > Engine Running Hot And/Or Loss of Coolant Radiator Cap: All Technical Service Bulletins Engine - Running Hot And/Or Loss of Coolant Bulletin No.: 00-06-02-001 File In Section: 06 Engine/Propulsion System Date: January, 2000 Subject: Engine Running Hot, Overheating and/or Loss of Coolant (Polish Radiator Filler Neck and Replace Radiator Cap) Models: 1999-2000 Passenger Cars and Trucks with Composite Radiator End Tank Condition Some customers may comment on one or more of the following conditions: ^ Engine running hot ^ Engine overheating, and/or ^ Loss of coolant/low coolant message Cause The radiator filler neck may have an imperfection in the sealing surface. Correction Important: DO NOT REPLACE THE RADIATOR. Using a piece of 400 grit wet/dry sandpaper backed with a flat piece of wood, polish the filler neck sealing surface using a circular motion. Replace the radiator pressure cap with a cap of the same part number as shown in the GM Service Parts Catalog. Warranty Information For vehicles repaired under warranty, use: Labor Labor Operation Description Time J3020 Cap, Radiator Filler - Replace 0.2 hr Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet Radiator Hose: Service and Repair Radiator Hose Replacement - Inlet Removal Procedure - Tools Required J 38185 Hose Clamp Pliers 1. Partially drain the cooling system. Refer to Draining and Filling Cooling System. 2. Remove the left diagonal brace. Refer to Brace Replacement - Front Fender Upper Diagonal (impala) or Brace Replacement - Front Fender Upper Diagonal (Monte Carlo) in Body and Frame. 3. Use the J 38185 in order to reposition the hose clamp at the thermostat housing. Disconnect the inlet hose (1) from the thermostat housing 4. Use the J 38185 in order to reposition the hose clamp at the radiator. 5. Disconnect the inlet hose from the radiator. Remove the inlet hose. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 3632 1. Align the marks on the hose. Install the inlet hose to the radiator. 2. Use the J 38185 in order to reposition and install the hose clamp at the radiator. 3. Connect the inlet hose (1) to the thermostat housing. 4. Use the J 38185 in order to reposition and install the inlet hose at the thermostat housing. 5. Install the left diagonal brace. Refer to Brace Replacement - Front Fender Upper Diagonal (Impala) or Brace Replacement - Front Fender Upper Diagonal (Monte Carlo) in Body and Frame. 6. Fill the cooling system. Refer to Draining and Filling Cooling System. 7. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 3633 Radiator Hose: Service and Repair Radiator Hose Replacement - Outlet Removal Procedure - Tools Required J 38185 Hose Clamp Pliers 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Use the J 38185 in order to reposition the hose clamp at water pump housing. 3. Disconnect the outlet hose (2) from the water pump housing. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Remove the radiator lower air deflector. Refer to Radiator Air Baffle Assemblies and Deflectors (Upper) or Radiator Air Baffle Assemblies and Deflectors (Side) or Radiator Air Baffle Assemblies and Deflectors (Lower). 6. Use the J 38185 in order to reposition the hose clamp at radiator. 7. Disconnect the outlet hose from the radiator. Remove the outlet hose. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 3634 1. Align the marks on the hose. Install the outlet hose to the radiator. 2. Use the J 38185 in order to reposition and install the hose clamp at the radiator. 3. Install the radiator lower air deflector. Refer to Radiator Air Baffle Assemblies and Deflectors (Upper) or Radiator Air Baffle Assemblies and Deflectors (Side) or Radiator Air Baffle Assemblies and Deflectors (Lower). 4. Lower the vehicle. 5. Connect the outlet hose to the water pump housing (2). 6. Use the J 38185 in order to reposition and install the hose clamp at the water pump housing. 7. Fill the cooling system. Refer to Draining and Filling Cooling System. 8. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions Coolant Level Indicator Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3641 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3642 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3643 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3644 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3645 Coolant Level Indicator Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3646 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3647 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3648 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3649 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3650 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3651 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3652 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3653 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3654 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3655 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3656 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3657 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3658 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3659 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3660 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3661 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3662 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3663 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3664 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3665 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3666 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Coolant Level Indicator Module > Component Information > Diagrams > Page 3667 Coolant Level Indicator Module: Service and Repair Removal Procedure 1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 2. Partially drain the radiator. Refer to Draining and Filling Cooling System. 3. Disconnect the low coolant module electrical connector. 4. In order to unlock the low coolant module, lift one leg of the snap clip from its locked position and pull outward with a slight twisting motion. Remove the low coolant module. Installation Procedure 1. Lubricate the O-ring seal with coolant. 2. Position the snap clip leg in place. 3. Install the low coolant module. 4. Connect the low coolant module electrical connector. 5. Fill the radiator. Refer to Draining and Filling Cooling System. 6. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 7. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations The Coolant Fan Relays are located in the bottom underhood accessory junction block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor Relay: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3673 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3674 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3675 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3676 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3677 Radiator Cooling Fan Motor Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3678 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3679 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3680 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3681 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3682 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3683 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3684 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3685 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3686 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3687 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3688 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3689 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3690 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3691 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3692 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3693 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3694 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3695 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3696 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3697 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3698 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3699 Cooling Fan Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Customer Interest for Coolant Level Sensor: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON Coolant Level Sensor: Customer Interest Instruments - Low Coolant Indicator Always ON Bulletin No.: 04-06-02-007 Date: August 11, 2004 TECHNICAL Subject: Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination) Models: 2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue Condition Some customers may comment that the low engine coolant level indicator is always illuminated. Cause The cause of this condition may be due to engine oil contaminating the coolant. Possible sources of oil contamination are internal engine leaks, improper service procedures, or the addition of some types of anti-leak additives to the cooling system. Once in the coolant, the oil leaves deposits on the level sensor creating an insulating film. This film results in a false activation of the coolant level indicator. Correction Diagnose low coolant level system operation and check the sensor for oil contamination using the procedure listed below. Important: No coolant supplements should be used in GM cooling systems, other than what is approved and recommended by GM. The use of "aftermarket" over-the-counter sealing and cooling supplements may affect the operation of the low coolant level sensor. Discoloration of the coolant recovery bottle is normal and does not necessarily indicate that coolant contamination is present. Flush cooling system only when instructed by this bulletin. 1. Verify that the coolant is at proper level in the radiator and the coolant recovery bottle. If the coolant is low, add proper amount of 50/50 water and DEX-COOL(R) mixture. If the low coolant light operates properly, diagnose the cooling system for loss of coolant as outlined in SI. DO NOT proceed further with this bulletin. 2. Remove the low coolant level sensor. Refer to Coolant Level Module Replacement in the Engine Cooling sub-section. 3. With the key on, the engine off and the coolant level sensor disconnected from the vehicle wiring harness, observe the low coolant light: ^ Light is on - Chassis wiring or instrument cluster concern. Follow the appropriate diagnostic information in SI. ^ Light is out - Proceed to Step 4. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Customer Interest for Coolant Level Sensor: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON > Page 3709 4. With the key off, connect the coolant level sensor into the vehicle's wiring harness. Connect a ground wire (1) to the battery negative terminal. Using a sharp probe (3) attached to the ground wire, ground the coolant sensor probe (2) as shown in the illustration. Make sure a good contact is made. With the key on and the engine off, observe the low coolant light for at least 15 seconds. ^ Light is on - Replace the low coolant sensor and re-check system operation. ^ Light is out - Proceed to Step 5. 5. Using a small wire brush or emery cloth, polish the low coolant level sensor probe to remove any film or oxidation. The probe should be a bright brass color when finished. Use Brake Parts Cleaner to flush removed deposits from the low coolant sensor probe. Re-install the low coolant sensor into the vehicle and proceed to Step 6. 6. Flush the cooling system and install new DEX-COOL(R) mixture as outlined in the SI. Check the vehicle's warranty history to determine if any engine gasket had recently been changed. If there has not been a recent gasket replacement, locate and repair the source of the engine oil contamination. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Customer Interest for Coolant Level Sensor: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON > Page 3710 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Level Sensor: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON Coolant Level Sensor: All Technical Service Bulletins Instruments - Low Coolant Indicator Always ON Bulletin No.: 04-06-02-007 Date: August 11, 2004 TECHNICAL Subject: Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination) Models: 2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue Condition Some customers may comment that the low engine coolant level indicator is always illuminated. Cause The cause of this condition may be due to engine oil contaminating the coolant. Possible sources of oil contamination are internal engine leaks, improper service procedures, or the addition of some types of anti-leak additives to the cooling system. Once in the coolant, the oil leaves deposits on the level sensor creating an insulating film. This film results in a false activation of the coolant level indicator. Correction Diagnose low coolant level system operation and check the sensor for oil contamination using the procedure listed below. Important: No coolant supplements should be used in GM cooling systems, other than what is approved and recommended by GM. The use of "aftermarket" over-the-counter sealing and cooling supplements may affect the operation of the low coolant level sensor. Discoloration of the coolant recovery bottle is normal and does not necessarily indicate that coolant contamination is present. Flush cooling system only when instructed by this bulletin. 1. Verify that the coolant is at proper level in the radiator and the coolant recovery bottle. If the coolant is low, add proper amount of 50/50 water and DEX-COOL(R) mixture. If the low coolant light operates properly, diagnose the cooling system for loss of coolant as outlined in SI. DO NOT proceed further with this bulletin. 2. Remove the low coolant level sensor. Refer to Coolant Level Module Replacement in the Engine Cooling sub-section. 3. With the key on, the engine off and the coolant level sensor disconnected from the vehicle wiring harness, observe the low coolant light: ^ Light is on - Chassis wiring or instrument cluster concern. Follow the appropriate diagnostic information in SI. ^ Light is out - Proceed to Step 4. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Level Sensor: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON > Page 3716 4. With the key off, connect the coolant level sensor into the vehicle's wiring harness. Connect a ground wire (1) to the battery negative terminal. Using a sharp probe (3) attached to the ground wire, ground the coolant sensor probe (2) as shown in the illustration. Make sure a good contact is made. With the key on and the engine off, observe the low coolant light for at least 15 seconds. ^ Light is on - Replace the low coolant sensor and re-check system operation. ^ Light is out - Proceed to Step 5. 5. Using a small wire brush or emery cloth, polish the low coolant level sensor probe to remove any film or oxidation. The probe should be a bright brass color when finished. Use Brake Parts Cleaner to flush removed deposits from the low coolant sensor probe. Re-install the low coolant sensor into the vehicle and proceed to Step 6. 6. Flush the cooling system and install new DEX-COOL(R) mixture as outlined in the SI. Check the vehicle's warranty history to determine if any engine gasket had recently been changed. If there has not been a recent gasket replacement, locate and repair the source of the engine oil contamination. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Level Sensor: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON > Page 3717 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor 23 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3722 Coolant Temperature Sensor/Switch (For Computer): Locations LH side, top of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3725 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3726 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3727 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3728 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3729 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3730 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3731 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3732 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3733 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3734 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3735 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3736 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3737 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3738 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3739 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3740 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3741 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3742 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3743 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3744 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3745 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3746 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3747 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3748 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3749 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3750 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3751 Engine Coolant Temperature (ECT) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3752 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3753 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The engine coolant temperature sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance (100,000 ohms at -40°C/-40°F) while high temperature causes low resistance (70 ohms at 130° C/266° F). The PCM supplies a 5.0 volt signal to the engine coolant temperature sensor through a resistor in the PCM and measures the voltage. The voltage will be high when the engine is cold, and low when the engine is hot. By measuring the voltage, the PCM calculates the engine coolant temperature. Engine coolant temperature affects most systems the PCM controls. The scan tool displays engine coolant temperature in degrees. After engine startup, the temperature should rise steadily to about 90°C (194°F) then stabilize when thermostat opens. If the engine has not been run for several hours (overnight), the engine coolant temperature and intake air temperature displays should be close to each other. A hard fault in the engine coolant sensor circuit should set DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage, or DTC P0118 Engine Coolant Temperature (ECT) Sensor Circuit High Voltage, an intermittent fault should set a DTC P1114 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent Low Voltage, or DTC P1115 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent High Voltage. The DTC Diagnostic Aids also contains a chart to test for sensor resistance values relative to temperature. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3754 The ECT sensor (3) also contains another circuit which is used to operate the engine coolant temperature gauge located in the instrument panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3755 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Relieve coolant pressure. 3. Disconnect the ECT sensor electrical connector. 4. Using a deep well socket and extension, remove the sensor. INSTALLATION PROCEDURE 1. Coat the engine coolant temperature sensor threads with sealer P/N 9985253 or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the sensor in the engine. Tighten Tighten the sensor to 23 N.m (17 lb ft). 3. Connect the ECT sensor electrical connector. 4. Start the engine. 5. Inspect for leaks. 6. Inspect the coolant level. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Mechanical Specifications Thermostat: Mechanical Specifications Thermostat Bypass Pipe Bolt .............................................................................................................. ............................................................ 98 inch lbs. Thermostat Bypass Pipe Nut ............................... ............................................................................................................................................... 18 ft. lbs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Mechanical Specifications > Page 3760 Thermostat: Pressure, Vacuum and Temperature Specifications Thermostat Temperature Range Starts To Open 87 Degrees C 188 Degrees F Fully Open 97 Degrees C 206 Degrees F Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement Thermostat: Service and Repair Thermostat Bypass Pipes Replacement Removal Procedure - Tools Required J 38185 Hose Clamp Pliers 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Carefully remove the throttle body air inlet duct. 3. Remove the LH engine mount strut. Refer to Engine Mount Strut Replacement (Left) or Engine Mount Strut Replacement (Right). 4. Disconnect the left bank spark plugs wires. Refer to Spark Plug Wire Harness Replacement in Powertrain Management. 5. Use the J 38185 in order to reposition the radiator inlet hose clamp at the thermostat housing. 6. Disconnect the radiator inlet hose at the thermostat housing. 7. Disconnect the heater outlet hose (2) from the thermostat bypass pipe. 8. Disconnect the throttle body inlet (3) and outlet (4) hoses from the thermostat bypass pipe. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement > Page 3763 9. Remove the thermostat bypass pipe nut. 10. Use the J 38185 in order to reposition the hose clamp at the thermostat bypass pipe. 11. Disconnect the thermostat bypass pipe hose. 12. Remove the thermostat bypass pipe bolt. 13. Remove the thermostat bypass pipe. Installation Procedure 1. Install the thermostat bypass pipe. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the thermostat bypass pipe bolt. Tighten the thermostat bypass pipe bolt to 11 Nm (98 inch lbs.). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement > Page 3764 3. Connect the thermostat bypass pipe hose. 4. Use the J 38185 in order to reposition and install the hose clamp at the thermostat bypass pipe. 5. Install the thermostat bypass pipe nut. Tighten the thermostat bypass pipe nut to 25 Nm (18 ft. lbs.). 6. Connect the heater outlet hose (2) to the thermostat bypass pipe. 7. Connect the throttle body inlet (3) and outlet (4) hoses to the thermostat bypass pipe. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement > Page 3765 8. Connect the inlet hose at the thermostat housing. 9. Use the J 38185 in order to reposition and install the inlet hose clamp at the thermostat housing. 10. Install the left bank spark plugs wires. Refer to Spark Plug Wire Harness Replacement in Powertrain Management. 11. Install the LH engine mount strut. Refer to Engine Mount Strut Replacement (Left) or Engine Mount Strut Replacement (Right). 12. Carefully install the throttle body air inlet duct. 13. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 14. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement > Page 3766 Thermostat: Service and Repair Thermostat Replacement Removal Procedure - Tools Required J 38185 Hose Clamp Pliers 1. Carefully remove the throttle body air inlet duct. 2. Partially drain the cooling system. Refer to Draining and Filling Cooling System. 3. Use the J 38185 in order to reposition the hose clamp at the thermostat housing. 4. Disconnect the radiator hose from the thermostat housing. 5. Remove the exhaust crossover pipe. Refer to Exhaust Crossover Replacement. 6. Remove the thermostat housing bolts. 7. Remove the thermostat housing and the gasket. 8. Remove the thermostat. 9. Clean the mating surfaces. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement > Page 3767 Installation Procedure 1. Install the thermostat. 2. Install the thermostat housing and the gasket. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the thermostat housing bolts. Tighten the thermostat housing bolts to 25 Nm (18 ft. lbs.). 4. Install the exhaust crossover pipe. Refer to Exhaust Crossover Replacement. 5. Connect the radiator hose to the thermostat housing. 6. Use the J 38185 in order to reposition and install the hose clamp at the thermostat housing. 7. Carefully install the throttle body air inlet duct. 8. Fill the cooling system. Refer to Draining and Filling Cooling System. 9. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Thermostat Housing Bolt (3.4L) 18 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolt 89 in.lb Water Pump Pulley Bolt 18 ft.lb Water Outlet Bolt 18 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3774 Water Pump: Service and Repair Removal Procedure 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Remove the drive belt guard. 3. Loosen the water pump pulley bolts. 4. Remove the drive belt. Refer to Drive Belt Replacement. 5. Remove the water pump pulley bolts. 6. Remove the water pump pulley. 7. Remove the water pump bolts. 8. Remove the water pump (1). 9. Remove the water pump gasket (2). 10. Clean the water pump mating surfaces. Installation Procedure 1. Install the gasket (2). 2. Install the water pump (1). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3775 3. Install the water pump bolts. Tighten the water pump bolts to 10 Nm (89 inch lbs.). 4. Install the water pump pulley. 5. Tighten the water pump pulley bolts. Tighten the water pump pulley bolts to 25 Nm (18 inch lbs.). 6. Install the drive belt. Refer to Drive Belt Replacement. 7. Install the drive belt guard. 8. Fill the cooling system. Refer to Draining and Filling Cooling System. 9. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair Catalytic Converter: Service and Repair Removal Procedure The three way catalytic converter is serviced by replacing the entire assembly. Always replace the gasket at the front flange when servicing the three way catalytic converter. Never reinstall the original gasket. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the heated oxygen sensor electrical connector. 3. Remove the exhaust manifold pipe stud nuts. 4. Remove the catalytic converter bolts. 5. Remove the three way catalytic converter. 6. Remove the heated oxygen sensor. Refer to Heated Oxygen Sensor (H02S) Replacement (H02SI) or Heated Oxygen Sensor (HO2S) Replacement (H02S2) in Computers and Controls. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Page 3780 1. Install the heated oxygen sensor. Refer to Heated Oxygen Sensor (HO25) Replacement (H02S1) or Heated Oxygen Sensor (HO2S) Replacement (H02S2) in Computers and Controls. 2. Install a new exhaust manifold pipe gasket. Notice: Refer to Catalytic Converter Movement Notice in Service Precautions. 3. Install and support the three way catalytic converter. 4. Install the catalytic converter bolts. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Page 3781 5. Install the exhaust manifold pipe stud nuts. - Tighten the exhaust manifold pipe stud nuts to 32 Nm (24 ft. lbs.). - Tighten the catalytic converter bolts to 45 Nm (33 ft. lbs.). 6. Connect the heated oxygen sensor electrical connector. 7. Inspect for leaks and underbody contact. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Specifications Exhaust Crossover Pipe: Specifications Exhaust Crossover Pipe Heat Shield Bolt 89 in.lb Exhaust Crossover Pipe Nut/Stud 18 ft.lb Exhaust Crossover Pipe Bolt 18 ft.lb Exhaust Crossover Pipe Heat Shield Bolt 89 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Specifications > Page 3785 Exhaust Crossover Pipe: Service and Repair Removal Procedure 1. Carefully remove the throttle body air inlet duct. 2. Reposition the AIR pipe for access if equipped. Refer to AIR Check Valve/Pipe Replacement -Bank 1 or AIR Check Valve/Pipe Replacement -Bank 2 in Computers and Controls. 3. Remove the thermostat by-pass tube. Refer to Thermostat Bypass Pipes Replacement in Cooling System. 4. Remove the exhaust crossover heat shield bolts. 5. Remove the exhaust crossover heat shield. 6. Remove the exhaust crossover pipe nuts. 7. Remove the exhaust crossover pipe. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Specifications > Page 3786 1. Install the exhaust crossover pipe. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the exhaust crossover pipe nuts. Tighten the exhaust crossover pipe nuts to 25 Nm (18 ft. lbs.). 3. Install the exhaust crossover heat shield. 4. Install the exhaust crossover heat shield bolts. Tighten the exhaust crossover heat shield bolts to 10 Nm (89 inch lbs.). 5. Install the thermostat by-pass tube. Refer to Thermostat Bypass Pipes Replacement in Cooling System. 6. Install the AIR pipe if equipped. Refer to AIR Check Valve/Pipe Replacement - Bank 1 or AIR Check Valve/Pipe Replacement - Bank 2 in Computers and Controls. 7. Carefully install the throttle body air inlet duct. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold Nut 12 ft.lb Exhaust Manifold Stud 13 ft.lb Exhaust Manifold-to-Cylinder Head Nuts 12 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Left Removal Procedure 1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 2. Carefully disconnect the throttle body air inlet duct. 3. Remove the right engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement (Upper) or Engine Mount Strut Bracket Replacement (Left) or Engine Mount Strut Bracket Replacement (Right). 4. Remove the AIR pipe if equipped. Refer to AIR Check Valve/Pipe Replacement - Bank 1 in Computers and Controls. 5. Remove the thermostat bypass pipe. 6. Remove the exhaust crossover pipe heat shield. Refer to Exhaust Crossover Replacement. 7. Remove the exhaust crossover pipe nuts to the left exhaust manifold. Refer to Exhaust Crossover Replacement. 8. Remove the left exhaust manifold heat shield bolts. 9. Remove the left exhaust manifold heat shield. 10. Remove the left exhaust manifold nuts. 11. Remove the left exhaust manifold. 12. Remove the left exhaust manifold gasket. 13. Clean the left exhaust manifold to the left cylinder head sealing surfaces. Refer to Exhaust Manifold Clean and Inspect. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 3792 1. Install the left exhaust manifold gasket. 2. Install the left exhaust manifold. Refer to Exhaust Manifold Installation (Left Side). 3. Install the left exhaust manifold heat shield. Refer to Exhaust Manifold Installation (Left Side). 4. Install the exhaust crossover pipe nuts to the left exhaust manifold. Refer to Exhaust Crossover Replacement. 5. Install the exhaust crossover pipe heat shield. Refer to Exhaust Crossover Replacement. 6. Install the AIR pipe if equipped. Refer to AIR Check Valve/Pipe Replacement Bank 2 in Computers and Controls. 7. Install the right engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement (Upper) or Engine Mount Strut Bracket Replacement (Left) or Engine Mount Strut Bracket Replacement (Right). 8. Carefully install the throttle body air inlet duct. 9. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 3793 Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Right Removal Procedure 1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 2. Disconnect the throttle body air inlet duct. Refer to Air Cleaner Assembly Replacement in Computers and Controls. 3. Remove the AIR check valve/pipe if equipped. Refer to AIR Check Valve/Pipe Replacement -Bank 2 in Computers and Controls. 4. Remove the exhaust crossover pipe heat shield. Refer to Exhaust Crossover Replacement. 5. Remove the exhaust crossover pipe nuts to the right exhaust manifold. Refer to Exhaust Crossover Replacement. 6. Disconnect the oxygen sensor wiring harness connector. 7. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 8. Disconnect the three-way catalytic converter pipe from the right exhaust manifold. Refer to Catalytic Converter Replacement in Powertrain Management. 9. Remove the exhaust gas recirculation (EGR) valve from the intake manifold. Refer to EGR Valve Replacement in Computers and Controls. 10. Remove the right exhaust manifold upper heat shield bolts. 11. Remove the right exhaust manifold upper heat shield. 12. Remove the right exhaust manifold lower heat shield bolts. 13. Remove the right exhaust manifold lower heat shield. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 3794 14. Remove the right exhaust manifold nuts. 15. Remove the right exhaust manifold. 16. Remove the right exhaust manifold gasket. 17. Clean the right exhaust manifold to the right cylinder head sealing surfaces. Refer to Exhaust Manifold Clean and Inspect. 18. If replacing the right exhaust manifold remove the EGR valve pipe. 19. If replacing the right exhaust manifold remove the heated oxygen sensor (H02S). Refer to Heated Oxygen Sensor (H02S) Replacement (HO2S1) or Heated Oxygen Sensor (HO2S) Replacement (HO2S2) in Computers and Controls. Installation Procedure 1. If removed, install the heated oxygen sensor (H02S). Refer to Heated Oxygen Sensor (HO2S) Replacement (HO2S1) or Heated Oxygen Sensor (HO2S) Replacement (HO2S2) in Computers and Controls. 2. If removed, install the exhaust gas recirculation (EGR) valve pipe. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 3795 3. Install the right exhaust manifold gasket. Install the right exhaust manifold. Refer to Exhaust Manifold Installation (Right Side). 4. Install the right exhaust manifold heat shields. Refer to Exhaust Manifold Installation (Right Side). 5. Install the EGR valve to the intake manifold. Refer to EGR Valve Replacement in Computers and Controls. 6. Install the three-way catalytic converter pipe to the right exhaust manifold. Refer to Catalytic Converter Replacement in Powertrain Management. 7. Lower the vehicle. 8. Connect the oxygen sensor wiring harness connector. 9. Install the exhaust crossover pipe nuts to the right exhaust manifold. Refer to Exhaust Crossover Replacement. 10. Install the exhaust crossover pipe heat shield. Refer to Exhaust Crossover Replacement. 11. Install the AIR check valve/pipe if equipped. Refer to AIR Check Valve/Pipe Replacement - Bank 2 in Computers and Controls. 12. Install the throttle body air inlet duct. Refer to Air Cleaner Assembly Replacement in Computers and Controls. 13. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications Exhaust Pipe: Specifications Exhaust Pipe Front Heat Shield Bolt 66 in.lb Exhaust Pipe Heat Shield Bolt 17 in.lb Exhaust Pipe Rear Hanger Bolt 18 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe Replacement - Single Exhaust Exhaust Pipe: Service and Repair Exhaust Pipe Replacement - Single Exhaust The exhaust pipe is a part of the exhaust muffler with exhaust pipe and tail pipe on the single exhaust system. For the single exhaust system service, refer to Exhaust System Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe Replacement - Single Exhaust > Page 3801 Exhaust Pipe: Service and Repair Exhaust Pipe Replacement - Dual Exhaust Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Notice: Refer to Catalytic Converter Movement Notice in Service Precautions. 2. Suitably support the exhaust system. 3. Disconnect the insulators from the exhaust pipe. 4. Remove the catalytic converter bolts. 5. Remove the catalytic converter gasket. Important: The cut must be made approximately 38 mm (1.5 inch) from the mufflers to ensure adequate overlap for clamping. 6. Cut the exhaust pipe from the exhaust mufflers. 7. Remove the exhaust pipe from the vehicle. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe Replacement - Single Exhaust > Page 3802 1. Install the exhaust muffler inlet pipe clamps. Do not tighten the exhaust muffler inlet pipe clamp nuts. 2. Install the exhaust pipe to the mufflers. 3. Position the exhaust pipe under the vehicle and support the pipe. 4. Install the exhaust pipe to the insulators. 5. Align the exhaust system. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the exhaust muffler inlet pipe clamp nuts. Tighten the exhaust muffler inlet pipe clamp nuts to 50 Nm (37 ft. lbs.). 7. Install a new catalytic converter gasket. 8. Install the catalytic converter bolts. Tighten the catalytic converter bolts to 45 Nm (33 ft. lbs.). 9. Remove the support from the exhaust system. 10. Inspect for exhaust system leaks and underbody contact. 11. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe Replacement - Single Exhaust > Page 3803 Exhaust Pipe: Service and Repair Tail Pipe Replacment Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Notice: Refer to Catalytic Converter Movement Notice in Service Precautions. 2. Suitably support the exhaust system. 3. Loosen the tail pipe extension clamp. 4. Remove the exhaust tail pipe extension. Installation Procedure 1. Install and adjust the exhaust tail pipe extension before tightening the tail pipe extension clamp. Notice: Refer to Fastener Notice in Service Precautions. 2. Tighten the tail pipe extension clamp. Tighten the tail pipe extension clamp to 35 Nm (26 ft. lbs.). 3. Remove the support from the exhaust system. 4. Inspect the exhaust system for leaks and underbody contact. 5. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Muffler Hangers Replacement Exhaust Pipe/Muffler Hanger: Service and Repair Muffler Hangers Replacement (Impala Muffler Rear Hanger Bracket) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the exhaust pipe rear hanger insulators (3) from the exhaust muffler rear hanger bracket. 3. Remove the exhaust muffler rear hanger bracket bolts (2). 4. Remove the exhaust muffler rear hanger bracket (1). Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the exhaust muffler hanger bracket (1) and bolts (2) to the bumper rail. Tighten the exhaust muffler rear hanger bracket bolts to 25 Nm (18.4 ft. lbs.). 2. Install the exhaust pipe rear hanger insulators (3) to the exhaust muffler rear hanger bracket. 3. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Muffler Hangers Replacement > Page 3808 Exhaust Pipe/Muffler Hanger: Service and Repair Muffler Hangers Replacement (Exhaust Pipe Hanger) 1. The exhaust system uses several different hangers. Insulators are used in conjunction with the hangers to support the exhaust system. 2. The exhaust pipe hanger is welded during assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Muffler Hangers Replacement > Page 3809 Exhaust Pipe/Muffler Hanger: Service and Repair Muffler Hangers Replacement (Pipe Rear Hanger Bracket) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the exhaust pipe rear hanger insulator from the exhaust pipe rear hanger bracket. 3. Remove the exhaust pipe rear hanger screw from the rear axle assembly. 4. Remove the exhaust pipe rear hanger bracket. Installation Procedure 1. Install the new exhaust pipe rear hanger bracket to the rear axle assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the exhaust pipe rear hanger screw. Tighten the exhaust pipe rear hanger screw to 25 Nm (18.4 ft. lbs.). 3. Install the exhaust pipe rear hanger insulator to the exhaust pipe rear hanger bracket. 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Muffler Hangers Replacement > Page 3810 Exhaust Pipe/Muffler Hanger: Service and Repair Muffler Hangers Replacement(Muffler Rear Hanger Bracket) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the exhaust pipe rear hanger insulators from the exhaust muffler rear hanger bracket. 3. Remove the inboard rear bumper impact bar bolt(s). 4. Loosen the lower outboard rear bumper impact bar bolt(s) (1, 4). 5. Remove the exhaust muffler rear hanger bracket(s) (2, 3). Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Muffler Hangers Replacement > Page 3811 1. Install the exhaust muffler hanger bracket(s) to the lower outboard rear bumper impact bar bolt(s). 2. Install the inboard rear bumper impact bar bolt(s). 3. Tighten the rear bumper impact bar bolts. Tighten the rear bumper impact bar bolts to 25 Nm (18.4 ft. lbs.). 4. Install the exhaust pipe rear hanger insulators to the exhaust muffler rear hanger bracket. 5. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications Heat Shield: Specifications Exhaust Manifold Heat Shield Bolt 89 in.lb Catalytic Converter Bolt 33 ft.lb Catalytic Converter Heat Shield Bolt 53 in.lb Catalytic Converter Heat Shield Nut 28 in.lb Exhaust Crossover Heat Shield Nut 15 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 3815 Heat Shield: Service and Repair Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Notice: Refer to Catalytic Converter Movement Notice in Service Precautions. 2. Suitably support the exhaust system. 3. Remove the catalytic converter. Refer to Catalytic Converter Replacement. 4. Remove the oxygen sensor wiring harness from the catalytic converter heat shield. 5. Remove the catalytic converter heat shield pop rivets. 6. Remove the catalytic converter heat shield. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 3816 1. Install the catalytic converter heat shield. 2. Install the converter heat shield pop rivets. 3. Install the oxygen sensor wiring harness to the catalytic converter heat shield. 4. Install the catalytic converter. Refer to Catalytic Converter Replacement. 5. Remove the support from the exhaust system. 6. Inspect the exhaust system for leaks and underbody contact. 7. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications Muffler: Specifications Exhaust Muffler Inlet Pipe Clamp Nut 37 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Muffler Replacement (Dual - Left Side) Muffler: Service and Repair Muffler Replacement (Dual - Left Side) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Notice: Refer to Catalytic Converter Movement Notice in Service Precautions. 2. Suitably support the exhaust system. Important: The cut(s) must be made on the straight pipe closest to the curve coming out of the left-side exhaust muffler (2). Do not cut on the curve or bend. 3. Cut the exhaust pipe closest to the left-hand exhaust muffler bend (1). 4. Disconnect the exhaust muffler rear hanger insulators from the exhaust muffler. 5. Remove the exhaust muffler. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Muffler Replacement (Dual - Left Side) > Page 3822 1. Install the exhaust muffler. 2. Connect the exhaust muffler rear hanger insulators to the exhaust muffler. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the exhaust muffler to the exhaust pipe. Tighten the exhaust muffler inlet pipe clamp nuts to 50 Nm (37 ft. lbs.). 4. Inspect the exhaust system for leaks and underbody contact. 5. Remove the support from the exhaust system. 6. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Muffler Replacement (Dual - Left Side) > Page 3823 Muffler: Service and Repair Muffler Replacement (Right Side) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Notice: Refer to Catalytic Converter Movement Notice in Service Precautions. 2. Suitably support the exhaust system. 3. Cut the exhaust pipe (1) as close as is possible to the muffler weld (2). 4. Disconnect the exhaust muffler rear hanger insulators from the exhaust muffler. 5. Remove the exhaust muffler. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Muffler Replacement (Dual - Left Side) > Page 3824 1. Connect the exhaust muffler to the exhaust muffler rear hanger insulators. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the exhaust muffler to the exhaust pipe. Tighten the exhaust muffler inlet pipe clamp nuts to 50 Nm (37 ft. lbs.). 3. Remove the support from the exhaust system. 4. Inspect the exhaust system for leaks and underbody contact. 5. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Body Control Module: Customer Interest BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 3836 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 Body Control Module: Customer Interest Body Control Module - MIL ON/DTCs B2647/B2648 File In Section: 08 - Body and Accessories Bulletin No.: 00-08-47-002 Date: September, 2000 Subject: Service Vehicle Soon (SVS) Message, DTC B2647 and/or B2648 Set (Replace Body Control Module) Models: 2000 Chevrolet Impala, Monte Carlo Built Prior to VIN Breakpoint Y9255551 Condition Some customers may comment about a "Service Vehicle Soon" message displayed, which may or may not store diagnostic codes (DTCs) B2647 and/or B2648. Cause The headlamp auto control ambient light sensor sends a brief voltage spike to the body control module (BCM) during engine crank, which may be detected as a fault by the BCM. This may initiate the SVS message. This voltage is considered a normal condition of the ambient light sensor. Correction Replace the body control module (BCM) to correct this condition. BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: ^ The vehicle will not be protected against theft by the Passlock(TM) system. ^ The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 3841 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (* )You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 3842 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 47. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 48. Select Set Options and press Enter. 49. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 50. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 51. Select Set Option Configuration and press Enter. 52. Press the key under the highlighted Done area of the Tech 2 display. 53. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 54. Exit back to the Main Menu screen. 55. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 56. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 57. Turn the ignition switch to OFF and wait 15 seconds. 58. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 59. The Security and Battery messages will begin toggling. 60. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 61. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 3843 62. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 63. The Security and Battery messages will begin toggling. 64. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 65. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 66. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 67. The Security and Battery messages will begin toggling. 68. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 69. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 70. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Parts Information The BCM part number has not changed, but the new BCM should have a code GMAB139 or higher on the label. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Body Control Module: All Technical Service Bulletins BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 3849 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-52-001 > Feb > 04 > Keyless Entry - BCM Set-Up Programming Body Control Module: All Technical Service Bulletins Keyless Entry - BCM Set-Up Programming Bulletin No.: 04-08-52-001 Date: February 25, 2004 INFORMATION Subject: Set-up/Programming BCM for Remote Keyless Entry (RKE) Models: 2000-2004 Chevrolet Impala, Monte Carlo In the past, when replacing the BCM on the above listed vehicles, the module had to be set-up to ensure the RKE was initiated. The RKE option RPO may not have been called out individually on the SPID label when the RKE option was part of an option package. This would often lead to this option being missed during BCM set-up and leading to an inoperative RKE feature. The new BCM, P/N 10350647, currently available, will automatically toggle the RKE function on during initiation of the module. Therefore, it is no longer necessary to turn on the RKE. Just leave it on regardless if the vehicle is equipped with RKE or not. This will prevent an incorrect set-up causing this feature to become inoperative. This new BCM will also remedy a situation where some older BCMs would not remember the horn chirp setting, short or long, after going into sleep mode. Also, this new BCM will not lock the settings until after 32 key cycles compared to 15 key cycles on older BCMs. So, if a mistake is made during the initial set-up, you can re-set the module. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 Body Control Module: All Technical Service Bulletins Body Control Module - MIL ON/DTCs B2647/B2648 File In Section: 08 - Body and Accessories Bulletin No.: 00-08-47-002 Date: September, 2000 Subject: Service Vehicle Soon (SVS) Message, DTC B2647 and/or B2648 Set (Replace Body Control Module) Models: 2000 Chevrolet Impala, Monte Carlo Built Prior to VIN Breakpoint Y9255551 Condition Some customers may comment about a "Service Vehicle Soon" message displayed, which may or may not store diagnostic codes (DTCs) B2647 and/or B2648. Cause The headlamp auto control ambient light sensor sends a brief voltage spike to the body control module (BCM) during engine crank, which may be detected as a fault by the BCM. This may initiate the SVS message. This voltage is considered a normal condition of the ambient light sensor. Correction Replace the body control module (BCM) to correct this condition. BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: ^ The vehicle will not be protected against theft by the Passlock(TM) system. ^ The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 3858 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (* )You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 3859 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 47. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 48. Select Set Options and press Enter. 49. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 50. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 51. Select Set Option Configuration and press Enter. 52. Press the key under the highlighted Done area of the Tech 2 display. 53. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 54. Exit back to the Main Menu screen. 55. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 56. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 57. Turn the ignition switch to OFF and wait 15 seconds. 58. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 59. The Security and Battery messages will begin toggling. 60. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 61. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 3860 62. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 63. The Security and Battery messages will begin toggling. 64. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 65. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 66. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 67. The Security and Battery messages will begin toggling. 68. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 69. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 70. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Parts Information The BCM part number has not changed, but the new BCM should have a code GMAB139 or higher on the label. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure Body Control Module: All Technical Service Bulletins BCM - Related Service, Theft Deterrent Relearn Procedure File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-057A Date: May, 2000 INFORMATION Subject: Body Control Module (BCM) Related Service, Theft Deterrent Re-Learn Procedure Models: 2000 Chevrolet Impala, Monte Carlo This bulletin is being revised to update the service procedure and the labor time information. Please discard Corporate Bulletin Number 99-06-O4-057 (Section 6 - Engine/Propulsion System). BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: - The vehicle will not be protected against theft by the Passlock(TM) system. - The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 3865 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (*) You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 3866 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. 47. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 48. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 49. Select Set Options and press Enter. 50. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 51. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 52. Select Set Option Configuration and press Enter. 53. Press the key under the highlighted Done area of the Tech 2 display. 54. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 55. Exit back to the Main Menu screen. 56. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 57. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 58. Turn the ignition switch to OFF and wait 15 seconds. 59. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 60. The Security and Battery messages will begin toggling. 61. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 62. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 63. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 64. The Security and Battery messages will begin toggling. 65. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 66. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 67. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 3867 release the ignition switch to the RUN position (the engine will not crank). 68. The Security and Battery messages will begin toggling. 69. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 70. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 71. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N4800 Computer (Control), Body - 1.1 hrs Replace and Program Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn Body Control Module: All Technical Service Bulletins BCM - Related Service. Theft Deterrent Relearn File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-057 Date: November, 1999 INFORMATION Subject: Body Control Module (BCM) Related Service, Theft Deterrent Re-Learn Procedure Models: 2000 Chevrolet Impala, Monte Carlo BCM replacement requires that a programming function be performed. If the BCM is not properly programmed, the vehicle may not start because the Theft Lock System will be enabled. Important: If the module is not properly programmed within twenty (20) key cycles (including the VIN), the module will lock and programming will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reprogrammed. When replacing the BCM, a critical component of the procedure requires a programming of the BCM. To program the BCM, follow all of the steps in the procedure listed. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "setup new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: - The vehicle will not be protected against theft by the Passlock(TM) system. - The engine will not crank or start. Programming of the BCM requires the use of the Tech 2 scan tool. 1. Insure that the key (or ignition) switch is in the LOCK position with the ignition off. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the key to the ON position. 4. The following items all refer to the Tech 2 scan tool inputs: ^ Select Diagnostics and answer the questions when prompted by the Tech 2. ^ Select Body Control Module (BCM). ^ Select Special Functions. ^ Select New VIN and input the required data. ^ Exit back to the Special Functions menu. 5. Select BCM Programming. 6. Press the YES key when the following message is displayed: Do you want to setup a body control module? 7. The Tech 2 will then display the following message: Now setting up the New Body Control Module. 8. When the BCM has been setup successfully, the Tech 2 will display this message: Body Control Module setup is complete. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 3872 THIS MEANS THAT THE TECH 2 HAS SET THE BCM TO ACCEPT THE CORRECT INFORMATION. THIS IS NOT THE END OF THE PROGRAMMING PROCEDURE. 9. Exit back to the Special Functions menu. 10. Select Set Options. 11. Input all of the required data as prompted by the Tech 2. 12. Exit back to the Special Functions menu. 13. Select Option Configuration. 14. Input all of the required data as prompted by the Tech 2. 15. When the BCM, VIN, Point of Sale and option configuration have been entered, proceed with the Theft Deterrent Re-Learn Procedure. IF THE TECH 2 DISPLAYS "UNABLE TO PROGRAM THE BCM", THE BCM IS LOCKED. TWENTY KEY CYCLES HAVE OCCURRED SINCE THE MODULE WAS INSTALLED AND VOLTAGE WAS SUPPLIED TO THE MODULE SO THE MODULE MUST BE REPLACED AND THIS PROCEDURE MUST BE REPEATED IN ITS ENTIRETY. Important: Programming of the BCM removes any personalization settings the customer may have previously set. Inform the customer the personalization settings will have to be reset. Theft Deterrent Re-Learn Important: Perform the Theft Deterrent Re-Learn Procedure when one or more of the following conditions has occurred. - The BCM has been replaced or re-programmed (Set-up) (Configured). - The ignition key cylinder assembly has been replaced. The Theft Deterrent Re-Learn Procedure can be accomplished two different ways depending on the equipment you have available. ^ Using The Techline equipment and the Tech 2 scan tool. ^ Without Techline Equipment of any kind. This procedure takes 30 minutes and must not be shortened. USING TECHLINE EQUIPMENT AND THE TECH 2 SCAN TOOL 1. If you disconnected the scan tool from the DLC, perform the following 3 steps. If it is still connected, proceed to step 5. 2. Ensure that the key (or ignition) switch is in the LOCK position with the ignition off. 3. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 4. Turn the key to the ON position. 5. From the Main Menu screen of the Tech 2, select Service Programming. 6. Enter the requested information. 7. Select Request Info. 8. When the Tech 2 finishes gathering the information, disconnect the Tech 2 from the DLC. 9. Connect the Tech 2 to the Techline terminal. 10. Select Service Programming System (SPS). 11 Select Terminal to Tech 2 programming. 12. Select Done. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 3873 13. Follow the instructions displayed on the Techline terminal for hand-held communications set-up screen. 14. Select Theft Module Re-Learn. 15. Select program at the summary screen. The terminal will now download information into the Tech 2. 16. Disconnect the Tech 2 from the Techline terminal. 17. Re-connect the Tech 2 to the DLC. 18. At the Scan Tool Main Menu, select Service Programming. 19. Answer the Tech 2 question. 20. Select Re-Learn. 21. The PCM and BCM are now prepared for the Re-Learn procedure to begin. 22. An internal security timer will now start. The security timer is 10 minutes in duration. Important: During this 10 minute period, the scan tool must NOT be disconnected from the vehicle. Does the Tech 2 display any kind of message telling you to proceed? 23. Turn the ignition switch to the OFF position. 24. Start the engine. The engine should start and continue to run. 25. The Theft Re-Learn procedure is complete. Look for any DTCs which may have been set during this procedure. If codes were set, clear them now. Remove the Tech 2 from the vehicle. WITHOUT TECHLINE EQUIPMENT OF ANY KIND This procedure takes 30 minutes and must not be shortened. 1. Ensure that the battery is fully charged before starting this procedure. 2. Turn the ignition switch to the OFF position. 3. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 4. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 5. Turn the ignition switch to the OFF position for 5 seconds. 6. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 7. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 8. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 9. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 10. Turn the ignition switch to the OFF position for 5 seconds. 11. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will now start. 12. Using the Tech 2, look for a Clear All Trouble Codes (DTCs). Warranty Information For vehicles repaired under warranty, use: Operation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 3874 Labor Description Labor Time N4800 Computer (Control), Body - 0.7 hr Replace and Program Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 04-08-52-001 > Feb > 04 > Keyless Entry - BCM Set-Up Programming Body Control Module: All Technical Service Bulletins Keyless Entry - BCM Set-Up Programming Bulletin No.: 04-08-52-001 Date: February 25, 2004 INFORMATION Subject: Set-up/Programming BCM for Remote Keyless Entry (RKE) Models: 2000-2004 Chevrolet Impala, Monte Carlo In the past, when replacing the BCM on the above listed vehicles, the module had to be set-up to ensure the RKE was initiated. The RKE option RPO may not have been called out individually on the SPID label when the RKE option was part of an option package. This would often lead to this option being missed during BCM set-up and leading to an inoperative RKE feature. The new BCM, P/N 10350647, currently available, will automatically toggle the RKE function on during initiation of the module. Therefore, it is no longer necessary to turn on the RKE. Just leave it on regardless if the vehicle is equipped with RKE or not. This will prevent an incorrect set-up causing this feature to become inoperative. This new BCM will also remedy a situation where some older BCMs would not remember the horn chirp setting, short or long, after going into sleep mode. Also, this new BCM will not lock the settings until after 32 key cycles compared to 15 key cycles on older BCMs. So, if a mistake is made during the initial set-up, you can re-set the module. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure Body Control Module: All Technical Service Bulletins BCM - Related Service, Theft Deterrent Relearn Procedure File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-057A Date: May, 2000 INFORMATION Subject: Body Control Module (BCM) Related Service, Theft Deterrent Re-Learn Procedure Models: 2000 Chevrolet Impala, Monte Carlo This bulletin is being revised to update the service procedure and the labor time information. Please discard Corporate Bulletin Number 99-06-O4-057 (Section 6 - Engine/Propulsion System). BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: - The vehicle will not be protected against theft by the Passlock(TM) system. - The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 3884 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (*) You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 3885 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. 47. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 48. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 49. Select Set Options and press Enter. 50. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 51. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 52. Select Set Option Configuration and press Enter. 53. Press the key under the highlighted Done area of the Tech 2 display. 54. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 55. Exit back to the Main Menu screen. 56. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 57. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 58. Turn the ignition switch to OFF and wait 15 seconds. 59. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 60. The Security and Battery messages will begin toggling. 61. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 62. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 63. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 64. The Security and Battery messages will begin toggling. 65. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 66. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 67. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 3886 release the ignition switch to the RUN position (the engine will not crank). 68. The Security and Battery messages will begin toggling. 69. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 70. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 71. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N4800 Computer (Control), Body - 1.1 hrs Replace and Program Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn Body Control Module: All Technical Service Bulletins BCM - Related Service. Theft Deterrent Relearn File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-057 Date: November, 1999 INFORMATION Subject: Body Control Module (BCM) Related Service, Theft Deterrent Re-Learn Procedure Models: 2000 Chevrolet Impala, Monte Carlo BCM replacement requires that a programming function be performed. If the BCM is not properly programmed, the vehicle may not start because the Theft Lock System will be enabled. Important: If the module is not properly programmed within twenty (20) key cycles (including the VIN), the module will lock and programming will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reprogrammed. When replacing the BCM, a critical component of the procedure requires a programming of the BCM. To program the BCM, follow all of the steps in the procedure listed. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "setup new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: - The vehicle will not be protected against theft by the Passlock(TM) system. - The engine will not crank or start. Programming of the BCM requires the use of the Tech 2 scan tool. 1. Insure that the key (or ignition) switch is in the LOCK position with the ignition off. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the key to the ON position. 4. The following items all refer to the Tech 2 scan tool inputs: ^ Select Diagnostics and answer the questions when prompted by the Tech 2. ^ Select Body Control Module (BCM). ^ Select Special Functions. ^ Select New VIN and input the required data. ^ Exit back to the Special Functions menu. 5. Select BCM Programming. 6. Press the YES key when the following message is displayed: Do you want to setup a body control module? 7. The Tech 2 will then display the following message: Now setting up the New Body Control Module. 8. When the BCM has been setup successfully, the Tech 2 will display this message: Body Control Module setup is complete. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 3891 THIS MEANS THAT THE TECH 2 HAS SET THE BCM TO ACCEPT THE CORRECT INFORMATION. THIS IS NOT THE END OF THE PROGRAMMING PROCEDURE. 9. Exit back to the Special Functions menu. 10. Select Set Options. 11. Input all of the required data as prompted by the Tech 2. 12. Exit back to the Special Functions menu. 13. Select Option Configuration. 14. Input all of the required data as prompted by the Tech 2. 15. When the BCM, VIN, Point of Sale and option configuration have been entered, proceed with the Theft Deterrent Re-Learn Procedure. IF THE TECH 2 DISPLAYS "UNABLE TO PROGRAM THE BCM", THE BCM IS LOCKED. TWENTY KEY CYCLES HAVE OCCURRED SINCE THE MODULE WAS INSTALLED AND VOLTAGE WAS SUPPLIED TO THE MODULE SO THE MODULE MUST BE REPLACED AND THIS PROCEDURE MUST BE REPEATED IN ITS ENTIRETY. Important: Programming of the BCM removes any personalization settings the customer may have previously set. Inform the customer the personalization settings will have to be reset. Theft Deterrent Re-Learn Important: Perform the Theft Deterrent Re-Learn Procedure when one or more of the following conditions has occurred. - The BCM has been replaced or re-programmed (Set-up) (Configured). - The ignition key cylinder assembly has been replaced. The Theft Deterrent Re-Learn Procedure can be accomplished two different ways depending on the equipment you have available. ^ Using The Techline equipment and the Tech 2 scan tool. ^ Without Techline Equipment of any kind. This procedure takes 30 minutes and must not be shortened. USING TECHLINE EQUIPMENT AND THE TECH 2 SCAN TOOL 1. If you disconnected the scan tool from the DLC, perform the following 3 steps. If it is still connected, proceed to step 5. 2. Ensure that the key (or ignition) switch is in the LOCK position with the ignition off. 3. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 4. Turn the key to the ON position. 5. From the Main Menu screen of the Tech 2, select Service Programming. 6. Enter the requested information. 7. Select Request Info. 8. When the Tech 2 finishes gathering the information, disconnect the Tech 2 from the DLC. 9. Connect the Tech 2 to the Techline terminal. 10. Select Service Programming System (SPS). 11 Select Terminal to Tech 2 programming. 12. Select Done. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 3892 13. Follow the instructions displayed on the Techline terminal for hand-held communications set-up screen. 14. Select Theft Module Re-Learn. 15. Select program at the summary screen. The terminal will now download information into the Tech 2. 16. Disconnect the Tech 2 from the Techline terminal. 17. Re-connect the Tech 2 to the DLC. 18. At the Scan Tool Main Menu, select Service Programming. 19. Answer the Tech 2 question. 20. Select Re-Learn. 21. The PCM and BCM are now prepared for the Re-Learn procedure to begin. 22. An internal security timer will now start. The security timer is 10 minutes in duration. Important: During this 10 minute period, the scan tool must NOT be disconnected from the vehicle. Does the Tech 2 display any kind of message telling you to proceed? 23. Turn the ignition switch to the OFF position. 24. Start the engine. The engine should start and continue to run. 25. The Theft Re-Learn procedure is complete. Look for any DTCs which may have been set during this procedure. If codes were set, clear them now. Remove the Tech 2 from the vehicle. WITHOUT TECHLINE EQUIPMENT OF ANY KIND This procedure takes 30 minutes and must not be shortened. 1. Ensure that the battery is fully charged before starting this procedure. 2. Turn the ignition switch to the OFF position. 3. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 4. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 5. Turn the ignition switch to the OFF position for 5 seconds. 6. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 7. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 8. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 9. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 10. Turn the ignition switch to the OFF position for 5 seconds. 11. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will now start. 12. Using the Tech 2, look for a Clear All Trouble Codes (DTCs). Warranty Information For vehicles repaired under warranty, use: Operation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 3893 Labor Description Labor Time N4800 Computer (Control), Body - 0.7 hr Replace and Program Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Body Control Module: Component Locations Locations View LH side of the instrument panel, above parking brake. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 3896 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3899 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3900 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3901 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3902 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3903 Body Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3904 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3905 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3906 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3907 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3908 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3909 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3910 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3911 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3912 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3913 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3914 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3915 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3916 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3917 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3918 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3919 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3920 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3921 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3922 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3923 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3924 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3925 Body Control Module: Connector Views Body Control Module, C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3926 Body Control Module, C2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3927 Body Control Module, C3 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3928 Body Control Module: Electrical Diagrams Body Control Module Schematics: Door Lock Switches, LH Front Door Lock Assembly Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3929 Body Control Module Schematics: DRL Relay, Backup Relay And Ambient Light Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3930 Body Control Module Schematics: Headlamp Switch, Ignition Key Alarm Switch, Surveillance Switch And Park Brake Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3931 Body Control Module Schematics: Headlamp Dimmer Switch, Headlamp Relay, Parklamp Relay Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3932 Body Control Module Schematics: HORN Relay FOG LP Relay And Fog Lamp Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3933 Body Control Module Schematics: Interior Lights (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3934 Body Control Module Schematics: Interior Lights (Part 2 of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3935 Body Control Module Schematics: Power, Grounds and RAP Relay Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3936 Body Control Module Schematics: Brake Transaxle Shift Interlock Control, Rear Compartment Lid Release And Remote Control Door Lock Receiver Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3937 Body Control Schematics: Rear Defog Relay, Door Lock Cylinder Switches Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3938 Body Control Module Schematics: RF And Rear Door Lock Assemblys Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3939 Body Control Module Schematics: SEO Rear Compartment Lid Relay Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3940 Body Control Module Schematics: Traction Control Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description Body Control Module: Description and Operation Circuit Description General Information The Body Control Module (BCM) is capable of accomplishing multiple body control functions. Components directly connected to the BCM are controlled by the BCM's outputs. The BCM can control its outputs based on input information it obtains from sensors and switches that are directly connected to the BCM, or by borrowing information from other vehicle systems connected to the Class 2 serial data link. The BCM evaluates this information and controls certain body systems by commanding an output on or off. The BCM is also capable of commanding other vehicle systems to control functions that are not directly wired and/or controlled by the BCM. The BCM accomplishes this task by sending specific messages on the Class 2 serial data link. The vehicle system capable of performing such function will respond to the BCM message. The BCM performs these functions: ^ Audible warnings. ^ Interior lighting. ^ Automatic door locks. ^ Keyless entry (AUO option) ^ Passlock theft deterrent. ^ Content Theft (UA6 option) ^ Retained Accessory Power (RAP) RPO AUO, UA6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Audible Warnings ^ Key in ignition reminder. ^ Fasten seat belt reminder. ^ Fasten belts indicator control. ^ Parking brake reminder. ^ Turn signal reminder. ^ Low fuel reminder. ^ Headlamps ON reminder. ^ Last door closed locking confirmation. ^ Feature customization. Interior Lighting ^ Interior illumination control. ^ Delayed illumination. ^ Illuminated entry. ^ Exit illumination. ^ Theater dimming. ^ Keyless entry unlock illumination. ^ Inadvertent load (battery rundown) protection. Automatic Door Locks ^ All door unlock. ^ All door lock. ^ Last door closed locking. ^ Lockout prevention. ^ Lockout prevention override. ^ Shift into PARK unlock. ^ Shift out of PARK lock. ^ Remote driver door unlock. ^ Remote all door unlock. ^ Remote all door lock. Keyless Entry ^ Remote driver door unlock. ^ Remote all door unlock. ^ Remote all door lock. ^ Remote activation verification. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 3943 ^ Remote alarm. ^ Feature customization of remote activation verification. BCM Inputs The following components provide direct input to the BCM, plus other systems can use this input information in order to carry out certain functions: ^ A/C Request: Provides the BCM with a request signal to command the A/C compressor through the PCM via Class 2 serial data. ^ BCM Ground: Provides ground for BCM operation. ^ BCM Power: Provides voltage for BCM operation. ^ Courtesy Lights On: Provides the driver the ability to request illumination of the vehicle interior. ^ Crank Signal: Determines when the ignition switch is in the start position. ^ Dome Lamp Switch Input: Determines when the dome lamp switch (Headlamp Switch) is closed to request the dome lamp on. ^ Door Lock Switch: Door lock switch request to lock and unlock the vehicle doors. ^ Door Locks: Provides voltage for door lock actuator operation. ^ Door Open: Provides door ajar status. ^ Driver Door Open: Allows certain chime functions when the driver's door is open. ^ DRL Signal Low: This input provides the BCM with Information through an ambient light sensor for the DRL feature. ^ Exterior Lamps Off: Determines when the headlamp switch is in the OFF position. ^ Fog Lamp Switch input: This input provides the BCM with a request for fog lamps through a momentary switch connected to ground. ^ Headlamp Switch Input: Determines when the Headlamp switch is closed to request the headlamps on. ^ High Beam: Determines the status of the headlamp dimmer switch, so the BCM can send the instrument cluster a message, via Class 2, to turn on the high beam indicator. ^ Ignition 0 Signal: Determines when the ignition switch is in ACCESSORY, ON or START position. ^ Ignition 1 Signal: Determines when the ignition switch is in the ON and START positions. ^ Key In Ignition: Determines when the key is fully inserted in the ignition key cylinder. ^ Key Unlock: Determines the status of the door lock cylinder switches for content theft. ^ Lamp Request: This input requests the BCM to energize the Battery Rundown Protection relay after the car has been turned off and all the doors have been closed, so the interior lights can be turned on. ^ Park Brake Applied: Determines when the parking brake is applied. ^ Park Lamp Switch Input: Determines when the park lamp switch (Headlamp Switch) is closed to request the park lamps on. ^ Passlock Sensor Data: Reads the Passlock sensor security code. ^ Rear Compartment Ajar: Determines if the rear decklid is open or closed. ^ Rear Compartment Release: This input requests the BCM to open the rear compartment lid. ^ RFA Link: Provides an interface allowing the transfer of keyless entry information from the Remote Control Door Lock Receiver (RCDLR). ^ Serial Data: provides an interface with the PCM, EBCM, Radio, SDM, DIC and the IPC through the Class 2 serial data link. ^ Surveillance Switch Input: Determines when the surveillance switch is closed to request the surveillance mode. ^ Traction Control Request: This input provides the BCM with a request for Traction Control through a momentary switch connected to ground. BCM Outputs The BCM directly controls these outputs, plus other systems may request the BCM to control these outputs for certain functions: ^ All Door Lock: This output supplies voltage to the door lock actuators when the doors are commanded to lock. This output also supplies ground to all the door lock actuators when the doors are commanded to unlock. ^ Backup Lamp Relay Control: Provides ground to the Backup LP relay control circuit. ^ BTSI Solenoid Control: Provides ground to the Brake Transaxle Shift Interlock Control Solenoid. ^ Door Unlock: This output supplies voltage to the door lock actuators (except the driver door lock actuator) when the doors are commanded to unlock. This output also supplies ground to all the door lock actuators (except the driver door lock actuator) when the doors are commanded to lock. ^ Driver Door Unlock: This output supplies voltage to the driver door lock actuators when the doors are commanded to unlock. This output also supplies ground to the driver door lock actuator when the doors are commanded to lock. ^ DRL Relay Control: Provides ground to the DRL relay control circuit. ^ DRL 5 V Reference: Provides 5 Volts to the ambient light sensor. ^ Inadvertent Load Relay Control Output: Supplies ground to the battery rundown protection relay providing an inadvertent load (battery rundown) protection. ^ Fog Lamp Enable Control: Sends a ground signal to the fog lamp switch when the ignition switch on; this action enables the fog lamp switch. The fog lamps turn on when the fog lamp switch is enabled by the BCM. ^ Headlamp Relay Control: Provides ground to the Headlamp relay control circuit. ^ Horn: Sends a ground signal to the horn relay, sounding the horn for the keyless entry alarm function or the content theft system. ^ Inadvertent Relay Control: Provides ground to the Battery Rundown Protection relay control circuit. ^ Interior Dimming: Controls the voltage to the interior lights dimming system. ^ Load Management Control: Provides voltage to the Rear Defogger relay control circuit and the Heated Seats. ^ Park Lamp Relay Control: Provides ground to the Park Lamp relay control circuit. ^ Passlock Sensor Power: Provides B+ for Passlock sensor operation. ^ Passlock Sensor Ground: Provides ground to the Passlock sensor. ^ RAP Relay Control: Provides voltage to the RAP relay control feed circuit. ^ Rear Compartment Lid Release Output: Provides ground to Rear Compartment Lid Release Actuator. ^ RFA Link: Provides an interface allowing the transfer of keyless entry information to the Remote Control Door Lock Receiver (RCDLR). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 3944 ^ Serial Data: provides an interface with the PCM, EBCM, Radio, SDM, DIC and the IPC through the Class 2 serial data link. ^ Theater Dimming 1 Control: Supplies ground to activate the Footwell lamps. ^ Theater Dimming 2 Control: Supplies ground to activate the inside rear view mirror lamps, non SEO dome lamp, and the roof rail courtesy/reading lamps. BCM Wake-Up/Sleep State The BCM performs its functions in the wake-up state. The BCM enters the sleep state when active control or monitoring of system malfunctions has stopped, or when the BCM is idling. The BCM must detect certain wake-up inputs before entering the wake-up state. The BCM monitors its inputs during the sleep state, allowing the BCM to switch between the two states, awake or asleep. The BCM enters the wake-up state when receiving activity on any of these inputs: ^ I/P dimmer switch. ^ Door lock (ajar) switch. ^ Door lock switch. ^ A keyless entry system signal. ^ Inadvertent power (battery rundown) protection transition. ^ The ignition is turned to the LOCK, ACCESSORY or the ON position. The sleep state is when the BCM has stopped active control and monitoring of system functions and has become idle again. For the BCM to enter the wake-up state, the BCM must detect a wake-up condition, mentioned previously. These conditions are called wake-up inputs that cause the BCM to change from a sleep to a wake-up state and begin active control and monitoring. The BCM has the ability to monitor for these wake-up inputs in the sleep state. The BCM enters the sleep state when all of these conditions exist: ^ No activity on the Class 2 serial data link. ^ The ignition switch is in the OFF position. ^ The BCM is not commanding any outputs. ^ No delay timers are actively counting (during theft deterrent re-learn). ^ No wake-up inputs are present. Content Theft (UA6 Option) The Body Control Module features a content theft deterrent system which is designed to defer vehicle vandalism and theft. The content theft deterrent system performs these functions: ^ Flashes the headlamps ^ Sounds the horns ^ Disables fuel delivery to the engine The BCM monitors the following: ^ Status of the doors ^ Lock cylinders ^ Rear compartment lid ^ Power door locks ^ The keyless entry system The BCM operates the headlamps, horns and the theft deterrent indicator, thats in the radio, according to the mode of operation the system is in. The BCM also communicates a fuel enable signal to the Powertrain Control Module (PCM) when the system is armed. Refer to Content Theft Deterrent (CTD) Operation in Theft Deterrent for more information. RPO UA6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Miscellaneous Functions ^ BRAKE indicator lamp control: The BCM controls the state of the BRAKE indicator lamp based on the status of the parking brake switch by sending a message to the instrument cluster via the Class 2 serial data link. ^ Fog lamp enable control. The BCM controls fog lamp operation, based on the status of the ignition switch. ^ Day/night mode sensing: The BCM determines the ambient light operating mode. The BCM then communicates the information to the Instrument Cluster and Powertrain Control Module (PCM) via the Class 2 serial data link. Passlock Theft Deterrent The Passlock is a vehicle theft deterrent system. The Passlock theft deterrent system contains a Passlock sensor. The Passlock sensor is part of the ignition lock cylinder assembly. The Body Control Module (BCM) provides power and ground to the Passlock sensor. The Passlock sensor interfaces with the BCM through the Passlock detection circuit. When turning the ignition switch to the start position with the proper key, the Passlock sensor generates an analog voltage signal. This signal is sent through the Passlock detecting circuit. This analog voltage signal is of a specific value to the vehicle, and varies from vehicle to vehicle. When attempting to start the engine, the BCM compares a preset stored analog voltage value with the signal coming from the sensor. Because both values Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 3945 match, the BCM sends a fuel enable password via the Class 2 serial data link to the Powertrain Control Module (PCM). As a result, the PCM enables the crank relay, and allows fuel delivery to the engine. When attempting to start the engine by means other than using the proper key in the ignition switch, the Passlock sensor sends an analog voltage signal of a different value. The BCM compares the preset stored analog voltage value with the signal coming from the sensor. Because both values do not match, the BCM sends a fuel disable password via the Class 2 serial data link to the Powertrain Control Module (PCM). As a result, the PCM disables the crank relay, and does not allow fuel delivery to the engine. Power Requirements The BCM has three main voltage feeds and two grounds. The voltage feed circuits are used to provide power for the BCM's logic, courtesy lights, internal driver operation and the door locks. Retained Accessory Power (RAP) The Accessory Power (RAP) feature allows the operation of the following functions for 10 minutes (or until a vehicle door opens) after the ignition switch has been turned from the ON or ACCESSORY position to the LOCK position: ^ The radio ^ The power windows ^ The power sunroof (if equipped) Refer to Keyless Entry System Operation in Retained Accessory Power (RAP) for more information. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 3946 Body Control Module: Description and Operation System Operation General Information The Body Control Module (BCM) is capable of accomplishing multiple body control functions. Components directly connected to the BCM are controlled by the BCM's outputs. The BCM can control its outputs based on input information it obtains from sensors and switches that are directly connected to the BCM, or by borrowing information from other vehicle systems connected to the Class 2 serial data link. The BCM evaluates this information and controls certain body systems by commanding an output on or off. The BCM is also capable of commanding other vehicle systems to control functions that are not directly wired and/or controlled by the BCM. The BCM accomplishes this task by sending specific messages on the Class 2 serial data link. The vehicle system capable of performing such function will respond to the BCM message. The BCM performs these functions: ^ Audible warnings. ^ Interior lighting. ^ Automatic door locks. ^ Keyless entry (AUO option) ^ Passlock theft deterrent. ^ Content Theft (UA6 option) ^ Retained Accessory Power (RAP) RPO UA6, AUO: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Audible Warnings ^ Key in ignition reminder. ^ Fasten seat belt reminder. ^ Fasten belts indicator control. ^ Parking brake reminder. ^ Turn signal reminder. ^ Low fuel reminder. ^ Headlamps ON reminder. ^ Last door closed locking confirmation. ^ Feature customization. Interior Lighting ^ Interior illumination control. ^ Delayed illumination. ^ Illuminated entry. ^ Exit illumination. ^ Theater dimming. ^ Keyless entry unlock illumination. ^ Inadvertent load (battery rundown) protection. Automatic Door Locks ^ All door unlock. ^ All door lock. ^ Last door closed locking. ^ Lockout prevention. ^ Lockout prevention override. ^ Shift into PARK unlock. ^ Shift out of PARK lock. ^ Remote driver door unlock. ^ Remote all door unlock. ^ Remote all door lock. Keyless Entry ^ Remote driver door unlock. ^ Remote all door unlock. ^ Remote all door lock. ^ Remote activation verification. ^ Remote alarm. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 3947 ^ Feature customization of remote activation verification. BCM Wake-Up/Sleep State The BCM performs its functions in the wake-up state. The BCM enters the sleep state when active control or monitoring of system malfunctions has stopped, or when the BCM is idling. The BCM must detect certain wake-up inputs before entering the wake-up state. The BCM monitors its inputs during the sleep state, allowing the BCM to switch between the two states, awake or asleep. The BCM enters the wake-up state when receiving activity on any of these inputs: ^ I/P dimmer switch. ^ Door lock (ajar) switch. ^ Door lock switch. ^ A keyless entry system signal. ^ Inadvertent power (battery rundown) protection transition. ^ The ignition is turned to the LOCK, ACCESSORY or the ON position. The sleep state is when the BCM has stopped active control and monitoring of system functions and has become idle again. For the BCM to enter the wake-up state, the BCM must detect a wake-up condition, mentioned previously. These conditions are called wake-up inputs that cause the BCM to change from a sleep to a wake-up state and begin active control and monitoring. The BCM has the ability to monitor for these wake-up inputs in the sleep state. The BCM enters the sleep state when all of these conditions exist: ^ No activity on the Class 2 serial data link. ^ The ignition switch is in the OFF position. ^ The BCM is not commanding any outputs. ^ No delay timers are actively counting (during theft deterrent re-learn). ^ No wake-up inputs are present. Content Theft (UA6 Option) The Body Control Module features a content theft deterrent system which is designed to defer vehicle vandalism and theft. The content theft deterrent system performs these functions: ^ Flashes the headlamps ^ Sounds the horns ^ Disables fuel delivery to the engine The BCM monitors the following: ^ Status of the doors ^ Lock cylinders ^ Rear compartment lid ^ Power door locks ^ The keyless entry system The BCM operates the headlamps, horns and the theft deterrent indicator, thats in the radio, according to the mode of operation the system is in. The BCM also communicates a fuel enable signal to the Powertrain Control Module (PCM) when the system is armed. Refer to Content Theft Deterrent (CTD) Operation in Theft Deterrent for more information. RPO UA6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Power Requirements The BCM has three main voltage feeds and two grounds. The voltage feed circuits are used to provide power for the BCM's logic, courtesy lights, internal driver operation and the door locks. BCM Inputs The following components provide direct input to the BCM, plus other systems can use this input information in order to carry out certain functions: ^ A/C Request: Provides the BCM with a request signal to command the A/C compressor through the PCM via Class 2 serial data. ^ BCM Ground: Provides ground for BCM operation. ^ BCM Power: Provides voltage for BCM operation. ^ Courtesy Lights On: Provides the driver the ability to request illumination of the vehicle interior. ^ Crank Signal: Determines when the ignition switch is in the start position. ^ Dome Lamp Switch Input: Determines when the dome lamp switch (Headlamp Switch) is closed to request the dome lamp on. ^ Door Lock Switch: Door lock switch request to lock and unlock the vehicle doors. ^ Door Locks: Provides voltage for door lock actuator operation. ^ Door Open: Provides door ajar status. ^ Driver Door Open: Allows certain chime functions when the driver's door is open. ^ DRL Signal Low: This input provides the BCM with Information through an ambient light sensor for the DRL feature. ^ Exterior Lamps Off: Determines when the headlamp switch is in the OFF position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 3948 ^ Fog Lamp Switch input: This input provides the BCM with a request for fog lamps through a momentary switch connected to ground. ^ Headlamp Switch Input: Determines when the Headlamp switch is closed to request the headlamps on. ^ High Beam: Determines the status of the headlamp dimmer switch, so the BCM can send the instrument cluster a message, via Class 2, to turn on the high beam indicator. ^ Ignition 0 Signal: Determines when the ignition switch is in ACCESSORY, ON or START position. ^ Ignition 1 Signal: Determines when the ignition switch is in the ON and START positions. ^ Key In Ignition: Determines when the key is fully inserted in the ignition key cylinder. ^ Key Unlock: Determines the status of the door lock cylinder switches for content theft. ^ Lamp Request: This input requests the BCM to energize the Battery Rundown Protection relay after the car has been turned off and all the doors have been closed, so the interior lights can be turned on. ^ Park Brake Applied: Determines when the parking brake is applied. ^ Park Lamp Switch Input: Determines when the park lamp switch (Headlamp Switch) is closed to request the park lamps on. ^ Passlock Sensor Data: Reads the Passlock sensor security code. ^ Rear Compartment Ajar: Determines if the rear decklid is open or closed. ^ Rear Compartment Release: This input requests the BCM to open the rear compartment lid. ^ RFA Link: Provides an interface allowing the transfer of keyless entry information from the Remote Control Door Lock Receiver (RCDLR). ^ Serial Data: provides an interface with the PCM, EBCM, Radio, SDM, DIC and the IPC through the Class 2 serial data link. ^ Surveillance Switch Input: Determines when the surveillance switch is closed to request the surveillance mode. ^ Traction Control Request: This input provides the BCM with a request for Traction Control through a momentary switch connected to ground. BCM Outputs The BCM directly controls these outputs, plus other systems may request the BCM to control these outputs for certain functions: ^ All Door Lock: This output supplies voltage to the door lock actuators when the doors are commanded to lock. This output also supplies ground to all the door lock actuators when the doors are commanded to unlock. ^ Backup Lamp Relay Control: Provides ground to the Backup LP relay control circuit. ^ BTSI Solenoid Control: Provides ground to the Brake Transaxle Shift Interlock Control Solenoid. ^ Door Unlock: This output supplies voltage to the door lock actuators (except the driver door lock actuator) when the doors are commanded to unlock. This output also supplies ground to all the door lock actuators (except the driver door lock actuator) when the doors are commanded to lock. ^ Driver Door Unlock: This output supplies voltage to the driver door lock actuators when the doors are commanded to unlock. This output also supplies ground to the driver door lock actuator when the doors are commanded to lock. ^ DRL Relay Control: Provides ground to the DRL relay control circuit. ^ DRL 5 V Reference: Provides 5 Volts to the ambient light sensor. ^ Inadvertent Load Relay Control Output: Supplies ground to the battery rundown protection relay providing an inadvertent load (battery rundown) protection. ^ Fog Lamp Enable Control: Sends a ground signal to the fog lamp switch when the ignition switch on; this action enables the fog lamp switch. The fog lamps turn on when the fog lamp switch is enabled by the BCM. ^ Headlamp Relay Control: Provides ground to the Headlamp relay control circuit. ^ Horn: Sends a ground signal to the horn relay, sounding the horn for the keyless entry alarm function or the content theft system. ^ Inadvertent Relay Control: Provides ground to the Battery Rundown Protection relay control circuit. ^ Interior Dimming: Controls the voltage to the interior lights dimming system. ^ Load Management Control: Provides voltage to the Rear Defogger relay control circuit and the Heated Seats. ^ Park Lamp Relay Control: Provides ground to the Park Lamp relay control circuit. ^ Passlock Sensor Power: Provides B+ for Passlock sensor operation. ^ Passlock Sensor Ground: Provides ground to the Passlock sensor. ^ RAP Relay Control: Provides voltage to the RAP relay control feed circuit. ^ Rear Compartment Lid Release Output: Provides ground to Rear Compartment Lid Release Actuator. ^ RFA Link: Provides an interface allowing the transfer of keyless entry information to the Remote Control Door Lock Receiver (RCDLR). ^ Serial Data: provides an interface with the PCM, EBCM, Radio, SDM, DIC and the IPC through the Class 2 serial data link. ^ Theater Dimming 1 Control: Supplies ground to activate the Footwell lamps. ^ Theater Dimming 2 Control: Supplies ground to activate the inside rear view mirror lamps, non SEO dome lamp, and the roof rail courtesy/reading lamps. Miscellaneous Functions ^ BRAKE indicator lamp control: The BCM controls the state of the BRAKE indicator lamp based on the status of the parking brake switch by sending a message to the instrument cluster via the Class 2 serial data link. ^ Fog lamp enable control. The BCM controls fog lamp operation, based on the status of the ignition switch. ^ Day/night mode sensing: The BCM determines the ambient light operating mode. The BCM then communicates the information to the Instrument Cluster and Powertrain Control Module (PCM) via the Class 2 serial data link. Passlock Theft Deterrent The Passlock is a vehicle theft deterrent system. The Passlock theft deterrent system contains a Passlock sensor. The Passlock sensor is part of the ignition lock cylinder assembly. The Body Control Module (BCM) provides power and ground to the Passlock sensor. The Passlock sensor interfaces with the BCM through the Passlock detection circuit. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 3949 When turning the ignition switch to the start position with the proper key, the Passlock sensor generates an analog voltage signal. This signal is sent through the Passlock detecting circuit. This analog voltage signal is of a specific value to the vehicle, and varies from vehicle to vehicle. When attempting to start the engine, the BCM compares a preset stored analog voltage value with the signal coming from the sensor. Because both values match, the BCM sends a fuel enable password via the Class 2 serial data link to the Powertrain Control Module (PCM). As a result, the PCM enables the crank relay, and allows fuel delivery to the engine. When attempting to start the engine by means other than using the proper key in the ignition switch, the Passlock sensor sends an analog voltage signal of a different value. The BCM compares the preset stored analog voltage value with the signal coming from the sensor. Because both values do not match, the BCM sends a fuel disable password via the Class 2 serial data link to the Powertrain Control Module (PCM). As a result, the PCM disables the crank relay, and does not allow fuel delivery to the engine. Retained Accessory Power (RAP) The Retained Accessory Power (RAP) feature allows the operation of the following functions for 10 minutes (or until a vehicle door opens) after the ignition switch has been turned from the ON or ACCESSORY position to the LOCK position: ^ The radio ^ The power windows ^ The power sunroof (if equipped) Refer to Keyless Entry System Operation in Retained Accessory Power (RAP) for more information. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Body Control Module: Initial Inspection and Diagnostic Overview A Diagnostic Starting Point - Body Control System Begin the diagnosis of the body control system by performing the Diagnostic System Check for the system in which the customer concern is apparent. The Diagnostic System Check will direct you to the correct procedure for diagnosing the system and where the procedure is located. A Diagnostic System Check - Body Control System A Diagnostic System Check-Body Control System TEST DESCRIPTION The number(s) below refer to the step number(s) on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 4. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Code Setting Criteria (Fault) For Device Power Moding Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3952 Body Control Module: Reading and Clearing Diagnostic Trouble Codes With Diagnostic Scan Tool PROCEDURE A Tech II or equivalent Scan tool must be used to retrieve Diagnostic Trouble Codes (DTCs) from the PCM or BCM memory. DTCs can no longer be retrieved at the data link connector. This also eliminates the PCM function of flashing Code 12. Follow the instructions supplied by the Scan tool manufacturer in order to access and read either current and/or history DTCs. Without Diagnostic Scan Tool A Tech II or equivalent scan tool must be used to retrieve Diagnostic Trouble Codes (DTCs) from the PCM memory. DTCs can no longer be retrieved at the data link connector. This also eliminates the PCM function of flashing Code 12. Follow the instructions supplied by the scan tool manufacturer in order to access and read either current and/or history DTCs. With Diagnostic Scan Tool PROCEDURE Use a Tech II or equivalent Scan tool to clear Diagnostic Trouble Codes (DTCs) from the PCM memory. When clearing DTCs, follow the instructions supplied by the Scan tool manufacturer. NOTES: ^ Do not clear the DTCs unless directed to do so by the service information provided for each diagnostic procedure. All of the diagnostic data that was saved along with the DTC (freeze frame data and/or malfunction history records) which may be helpful for some diagnostic procedures will be erased from the memory when the DTCs are cleared. ^ Interrupting PCM battery voltage to clear DTCs is NOT recommended. Without Diagnostic Scan Tool PROCEDURE Use a Tech II or equivalent Scan tool to clear Diagnostic Trouble Codes (DTCs) from the PCM memory. When clearing DTCs, follow the instructions supplied by the Scan tool manufacturer. NOTES: ^ Do not clear the DTCs unless directed to do so by the service information provided for each diagnostic procedure. All of the diagnostic data that was saved along with the DTC (freeze frame data and/or malfunction history records) which may be helpful for some diagnostic procedures will be erased from the memory when the DTCs are cleared. ^ Interrupting PCM battery voltage to clear DTCs is NOT recommended. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3953 Body Control Module: Scan Tool Testing and Procedures Scan Tool Data Definitions Doors Battery Fd: The scan tool displays Inactive/Active. The input of the Doors Battery Fd is displayed as Active. Electronics Battery Fd: The scan tool displays Inactive/Active. The input of the Electronics Battery Fd is displayed as Active. Electronics System Gnd: The scan tool displays Inactive/Active. The input of the Electronics System Gnd is displayed as Active. Ignition 0: The scan tool displays On/Off. The input of the Ignition 0 varies on the scan tool display. Ignition 1: The scan tool displays On/Off. The input of the Ignition 1 varies on the scan tool display. Ignition 3: The scan tool displays On/Off. The input of the Ignition 3 varies on the scan tool display. Inadvert Power Relay: The scan tool displays On/Off. The input of the Inadvert Power Output varies on the scan tool display Loads Battery Fd: The scan tool displays Inactive/Active. The input of the Loads Battery Fd is displayed as Active. Loads System Gnd: The scan tool displays Inactive/Active. The input of the Loads System Gnd is displayed as Active. Theater Dim 1 Ground: The scan tool displays Inactive/Active. The input of the Theater Dim 1 Ground is displayed as Inactive. Theater Dim 2 Ground: The scan tool displays Inactive/Active. The input of the Theater Dim 2 Ground is displayed as Inactive. Scan Tool Data List Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures Body Control Module (BCM) Programming/RPO Configuration INTRODUCTION During body control module (BCM) related service, the procedures below are designated to set-up the BCM correctly. Before you start, read these procedures carefully and completely. SETUP NEW BODY CONTROL MODULE (BCM) IMPORTANT: ^ The BCM will not function properly if the Setup New BCM procedure is not performed. ^ Make sure the battery is fully charged before performing the setup procedure. ^ Make sure all disconnected devices and connectors have been reconnected ^ Perform the Theft Deterrent Re-learn procedure after successfully finishing the Setup New BCM procedure. Refer to Programming Theft Deterrent System Components in Theft Deterrent. If the Theft Deterrent Re-learn procedure is not performed after a BCM replacement, the following conditions may occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank nor start. 1. Connect a scan tool to the data link connector (DLC). 2. Turn the ignition switch ON. 3. Select Diagnostics and input all of the required data when prompted by the scan tool. 4. Select BODY CONTROL MODULE. 5. Select SPECIAL FUNCTIONS. 6. Select Setup New BCM. 7. Note, Input all of the required data when prompted by the scan tool. 8. Select Setup SDM Part Number in BCM, and follow the onscreen directions. 9. Select New VIN, and follow the onscreen directions. 10. Select Option Configuration, and follow the onscreen directions. 11. Select Point of Sale, and follow the onscreen directions. 12. Exit back to the SPECIAL FUNCTIONS menu. 13. When the BCM, VIN, Point of Sale and Option Configuration have been entered, proceed with Theft Deterrent Re-learn procedure. 14. If the scan tool displays UNABLE TO PROGRAM BCM, BCM IS SECURED, then the BCM must be replaced and this procedure must be repeated on a new BCM.. NOTE: After the above procedure has been completed, personalization of the BCM defaults to a default setting. Inform the customer that the personalization settings must be set again. IMPORTANT: After programing, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve History DTCs from all modules. 5. Clear all history DTCs General Information During Body Control Module (BCM) related service, the procedures below are designated to set-up the BCM correctly. Before you start, read these procedures carefully and completely. Theft Deterrent Re-Learn Using T-50 or T-60 1. Enter the T-50 or T-60 Service Programming System (SPS). 2. Select TERMINAL TO VEHICLE PROGRAMMING. 3. Select DONE. 4. Follow the instructions on the VEHICLE SETUP screen. 5. Select THEFT MODULE RE-LEARN. 6. Follow the instructions on the remaining screens. 7. The PCM and BCM will be prepared for re-learn. 8. A security timer will be on for approximately 10 minutes. During the 10 minute wait period, the T-50 or T-60 terminal must remain connected to the vehicle. 9. When the PCM and BCM are prepared to re-learn, turn the ignition switch off. 10. Turn the ignition switch to start. The vehicle should now start. Theft Deterrent Re-Learn W/O Scan Tool Or Techline Equipment This procedure takes approximately 30 minutes. Make sure the battery is fully charged before proceeding. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 3956 1. Turn the ignition switch off. 2. Turn the ignition switch all the way from the off to the start position, then leave it in the on position. NOTE: The engine will not crank. 3. The SECURITY will come on and stay on for at least 10 minutes. 4. Turn the ignition switch off for five seconds. 5. Repeat steps 2, 3, and 4 again for a second time. 6. Repeat steps 2, 3, and 4 again for a third time. 7. Turn the ignition switch off. 8. Turn the ignition switch all the way to the start position. The engine should now start. 9. Check for BCM Diagnostic Trouble Codes (DTCs). Theft Deterrent Re-Learn With Techline Equip & Tech 2 Scan Tool 1. Connect the Scan Tool to the Data Link Connector (DLC) on the vehicle. 2. At the Scan Tool main menu, select SERVICE PROGRAMMING. 3. Enter the requested information. 4. Select REQUEST INFO. 5. Disconnect the Scan Tool from the vehicle. 6. Connect the Scan Tool to the Techline terminal. 7. Select SERVICE PROGRAMMING SYSTEM (SPS). 8. Select TERMINAL TO TECH 2 PROGRAMMING. 9. Select DONE. 10. Follow instructions on the Techline terminal to Handheld Communications Setup screen. 11. Select THEFT MODULE RE-LEARN. 12. Select PROGRAM at the summary screen. The terminal will download information to the Scan Tool. 13. Disconnect the Scan Tool from the Techline terminal. 14. Connect the Scan Tool to the DLC on the vehicle. 15. At the Scan Tool main menu, select SERVICE PROGRAMMING. 16. Answer the question prompted by the Scan Tool. 17. Select RE-LEARN. 18. The Powertrain Control Module (PCM) and the BCM will be prepared for re-learn. 19. A security timer will be on for approximately 10 minutes. During the 10 minute wait period, Scan Tool must remain connected to the vehicle. 20. Turn the ignition switch off when the re-learn procedure is complete. 21. Turn the ignition switch to the start position. 22. The engine should start when the ignition switch is turned to the start position. 23. Disconnect the Scan Tool from the DLC. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 3957 Body Control Module: Removal and Replacement Body Control Module Replacement REMOVAL PROCEDURE IMPORTANT: You must perform the new body control module (BCM) setup when replacing the BCM. Refer to BCM Programming/RPO Configuration. 1. Disconnect the battery ground (negative) cable. 2. Remove the left instrument panel insulator. 3. Disconnect the BCM electrical connectors (2, 3, 4). 4. Remove the BCM (1). INSTALLATION PROCEDURE 1. Install the body control module (BCM) (1). 2. Connect the BCM electrical connectors (2, 3, 4). 3. Install the left instrument panel insulator 4. Connect the battery ground (negative) cable. 5. Perform the new BCM setup. Refer to BCM Programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Powertrain Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 3962 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3963 Powertrain Control Module: Locations Locations View RH side of the engine compartment, forward of the strut tower, inside air box. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3966 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3967 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3968 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3969 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3970 Powertrain Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3971 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3972 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3973 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3974 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3975 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3976 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3977 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3978 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3979 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3980 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3981 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3982 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3983 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3984 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3985 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3986 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3987 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3988 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3989 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3990 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3991 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3992 Powertrain Control Module: Connector Views Powertrain Control Module Connector C1 End View (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3993 Powertrain Control Module Connector C1 End View (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3994 Powertrain Control Module Connector C2 End View (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3995 Powertrain Control Module Connector C2 End View (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > EEPROM Programming Powertrain Control Module: Service and Repair EEPROM Programming 1. The ignition is ON. 2. If the PCM fails to program, inspect the Techline equipment for the latest software version. 3. Attempt to program the PCM. If the PCM still cannot be programmed properly, replace the PCM. The replacement PCM must be programmed. Functional Check 1. Perform A Powertrain On Board Diagnostic (OBD) System Check. 2. Start the engine and let the engine run for one minute. 3. Use the scan tool in order to scan for the DTCs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > EEPROM Programming > Page 3998 Powertrain Control Module: Service and Repair PCM Replacement/Programming NOTE: In order to prevent possible Electrostatic Discharge damage to the PCM, Do Not touch the connector pins or the soldered components on the circuit board. Service of the PCM should normally consist of either replacement of the PCM or EEPROM programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if it is the correct part. If it is, remove the faulty PCM and install the new service PCM. NOTE: Turn the ignition OFF when installing or removing the PCM connectors and disconnecting or reconnecting the power to the PCM (battery cable, PCM pigtail, PCM fuse, jumper cables, etc.) in order to prevent internal PCM damage. IMPORTANT: When replacing the production PCM with a service PCM, it is important to transfer the broadcast code and production PCM number to the service PCM label. Do not record on PCM cover. This will allow positive identification of PCM parts throughout the service life of the vehicle. THE SERVICE PCM EEPROM WILL NOT BE PROGRAMMED. DTC P0602 indicates the EEPROM is not programmed or has malfunctioned. Removal Procedure CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Disconnect the IAT sensor electrical connector. 3. Remove the 3 bolts from the inner fender brace and remove the brace. 4. Loosen the clamps securing the air intake duct/MAF sensor to the air cleaner housing and throttle body. 5. Carefully remove the air intake duct/MAF sensor from the throttle body and air cleaner housing (1). 6. Remove the 2 screws (2) from the 2 air cleaner housing sections. 7. Remove the air cleaner housing cover assembly. 8. Without disconnecting the PCM connectors, remove the PCM (4) and harness from the PCM housing (3). 9. Disconnect the PCM connectors. Installation Procedure 1. Connect the PCM connectors. 2. Carefully install the PCM (4) and harness into the PCM housing (3). 3. Install the air cleaner housing cover assembly (1). 4. Install the 2 screws to the 2 air cleaner housing sections. 5. Carefully install the air intake duct to the throttle body and air cleaner housing. 6. Tighten the clamp securing the air intake duct to the air cleaner housing. 7. Position the inner fender brace and reinstall the 3 bolts. 8. Connect the Negative Battery Cable. 9. If a replacement PCM is being installed, program the PCM. The replacement PCM will NOT allow Secondary AIR Pump operation until a total of 10 miles have accumulated. 10. If a replacement PCM is being installed, perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Locations Underhood Fuse Block (Upper) - RH Engine Compartment Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Locations > Page 4003 Air Injection Pump Relay: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the underhood electrical center cover. 3. Remove the secondary air pump relay. INSTALLATION PROCEDURE 1. Install the secondary air pump relay. 2. Install the underhood electrical center cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4009 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4010 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4011 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4012 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4013 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4014 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4015 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4016 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4017 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4018 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4019 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4020 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4021 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4022 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4023 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4024 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4025 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4026 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4027 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4028 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4029 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4030 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4031 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4032 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4033 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4034 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 4035 Fuel Pump Relay: Service and Repair REMOVAL PROCEDURE 1. Turn the ignition OFF. 2. Remove the under hood electrical center cover. 3. Remove the fuel pump relay. INSTALLATION PROCEDURE 1. Install the fuel pump relay. 2. Install the under hood electrical center cover. 3. Turn the ignition ON. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Specifications Ignition Control Module: Specifications Ignition Coil to Ignition Control Module Screws 4.5 Nm Ignition Controle Module Bracket to Engine Studs and Nuts 25 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Component Locations > Page 4042 Ignition Control Module: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Component Locations > Page 4043 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Ignition Control Module C1 Ignition Control Module (ICM), C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Ignition Control Module C1 > Page 4046 Ignition Control Module (ICM), C2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 4047 Ignition Control Module: Description and Operation Ignition Control (IC) Module The Ignition Control (IC) module performs the following functions: ^ It determines the correct ignition coil firing sequence, based on 7X pulses. This coil sequencing occurs at start-up. After the engine is running, the module determines the sequence, and continues triggering the ignition coils in proper sequence. ^ It sends the 3X crankshaft reference (fuel control) signal to the PCM. The PCM determines engine RPM from this signal. this signal is also used by the PCM to determine crankshaft speed for ignition control (IC) spark advance calculations. The 3X reference signal sent to the PCM by the IC module is an on, off pulse occurring 3 times per crankshaft revolution. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 4048 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect all the electrical connectors at the ignition control module. 3. Note position of spark plug wires for installation and disconnect the spark plug wires from ignition coils. 4. Remove the screws securing coil assemblies to ignition control module. 5. Disconnect the coils from ignition control module. 6. Remove the fasteners securing ignition control module assembly to engine. 7. Remove the ignition control module from the module mounting bracket. INSTALLATION PROCEDURE 1. Install the ignition control module on the module mounting bracket. 2. Install the coils to ignition control module. 3. Reinstall the screws through the coils and module into the module mounting bracket. NOTE: Refer to Fastener Notice in Service Precautions. 4. Reinstall the screws. Tighten Tighten the screws to 4-5 N.m (40 lb in). 5. Connect the spark plug wires as noted during removal. 6. Connect the electrical connectors to the ignition control module. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations LF of the engine compartment, in the air cleaner duct. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions Mass Air Flow (MAF) Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4056 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4057 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4058 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4059 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4060 Mass Air Flow (MAF) Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4061 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4062 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4063 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4064 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4065 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4066 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4067 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4068 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4069 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4070 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4071 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4072 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4073 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4074 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4075 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4076 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4077 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4078 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4079 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4080 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4081 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4082 Mass Air Flow (MAF) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4083 Mass Air Flow (MAF) Sensor: Electrical Diagrams Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4084 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Page 4085 Mass Air Flow (MAF) Sensor: Description and Operation The Mass Air Flow (MAF) sensor measures the amount of air which passes through it. The PCM uses this information to determine the operating condition of the engine, to control fuel delivery. A large quantity of air indicates acceleration, while a small quantity indicates deceleration or idle. The scan tool reads the MAF value and displays it in grams per second (gm/s). At idle, it should read between 4 gm/s to 6 gm/s on a fully warmed up engine. Values should change rather quickly on acceleration, but values should remain fairly stable at any given RPM. A failure in the MAF sensor or circuit should set DTC P0101 Mass Air Flow (MAF) Sensor Performance, DTC P0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency, or DTC P0103 Mass Air Flow (MAF) Sensor Circuit High Frequency The MAF sensor is attached to the front (air inlet side) of the throttle body and is used to measure the amount of air entering the engine. The PCM uses this information to determine the operating condition of the engine and to control fuel delivery. For further information, refer to Information Sensors/Switches Description. See: Computers and Control Systems/Description and Operation/Information Sensors/Switches Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Page 4086 Mass Air Flow (MAF) Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the MAF sensor (1) electrical connector. 4. Remove the air inlet duct from the MAF sensor and the throttle body. 5. Remove the MAF sensor from the air filter housing. INSTALLATION PROCEDURE 1. Install the MAF sensor to the air filter housing. 2. Install the air inlet duct to the MAF sensor and throttle body. 3. Connect the IAT sensor (1) electrical connector. 4. Connect the MAF sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 89 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations RH side of the engine, below the intake plenum. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 4092 Camshaft Position Sensor: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 4093 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4096 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4097 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4098 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4099 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4100 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4101 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4102 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4103 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4104 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4105 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4106 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4107 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4108 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4109 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4110 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4111 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4112 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4113 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4114 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4115 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4116 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4117 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4118 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4119 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4120 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4121 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4122 Camshaft Position Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position (CMP) Sensor and Cam Signal Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor and Cam Signal The camshaft position sensor sends a cam signal to the PCM which uses it as a sync pulse to trigger the injectors in proper sequence. The PCM uses the CAM signal to indicate the position of the #1 piston during its intake stroke. This allows the PCM to calculate true Sequential Fuel Injection (SFI) mode of operation. If the PCM detects an incorrect CAM signal while the engine is running, DTC P0341 Camshaft Position (CMP) Sensor Performance will set. If the CAM signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection mode based on the last fuel injection pulse, and the engine will continue to run. The engine can be restarted and will run in the calculated sequential mode as long as the fault is present with a 1 in 6 chance of injector sequence being correct. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position (CMP) Sensor and Cam Signal > Page 4125 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The camshaft position sensor is located on the timing cover behind the water pump near the camshaft sprocket. As the camshaft sprocket turns, a magnet in it activates the Hall-effect switch in the camshaft position sensor. When the Hall-effect switch is activated, it grounds the signal line to the PCM, pulling the camshaft position sensor signal circuit's applied voltage low. This is interpreted as a CAM signal. The CAM signal is created as piston #1 is on the intake stroke. If the correct CAM signal is not received by the PCM, DTC P0341 will be set. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 4126 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the serpentine drive belt. 3. Loosen the power steering pump to gain access to the CMP. 4. Disconnect the sensor electrical connector. 5. Remove the attaching bolt. 6. Remove the sensor. 7. Inspect the sensor for wear, cracks or leakage if the sensor is not being replaced. INSTALLATION PROCEDURE 1. Lubricate the O-ring with clean engine oil and replace if damaged. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the camshaft position sensor. Tighten Tighten the retaining bolt to 10 N.m (88 lb in). 3. Connect the sensor electrical connector. 4. Install the power steering pump. 5. Reinstall the serpentine drive belt. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor 23 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4130 Coolant Temperature Sensor/Switch (For Computer): Locations LH side, top of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4133 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4134 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4135 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4136 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4137 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4138 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4139 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4140 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4141 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4142 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4143 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4144 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4145 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4146 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4147 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4148 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4149 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4150 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4151 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4152 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4153 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4154 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4155 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4156 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4157 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4158 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4159 Engine Coolant Temperature (ECT) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4160 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 4161 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The engine coolant temperature sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance (100,000 ohms at -40°C/-40°F) while high temperature causes low resistance (70 ohms at 130° C/266° F). The PCM supplies a 5.0 volt signal to the engine coolant temperature sensor through a resistor in the PCM and measures the voltage. The voltage will be high when the engine is cold, and low when the engine is hot. By measuring the voltage, the PCM calculates the engine coolant temperature. Engine coolant temperature affects most systems the PCM controls. The scan tool displays engine coolant temperature in degrees. After engine startup, the temperature should rise steadily to about 90°C (194°F) then stabilize when thermostat opens. If the engine has not been run for several hours (overnight), the engine coolant temperature and intake air temperature displays should be close to each other. A hard fault in the engine coolant sensor circuit should set DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage, or DTC P0118 Engine Coolant Temperature (ECT) Sensor Circuit High Voltage, an intermittent fault should set a DTC P1114 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent Low Voltage, or DTC P1115 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent High Voltage. The DTC Diagnostic Aids also contains a chart to test for sensor resistance values relative to temperature. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 4162 The ECT sensor (3) also contains another circuit which is used to operate the engine coolant temperature gauge located in the instrument panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 4163 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Relieve coolant pressure. 3. Disconnect the ECT sensor electrical connector. 4. Using a deep well socket and extension, remove the sensor. INSTALLATION PROCEDURE 1. Coat the engine coolant temperature sensor threads with sealer P/N 9985253 or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the sensor in the engine. Tighten Tighten the sensor to 23 N.m (17 lb ft). 3. Connect the ECT sensor electrical connector. 4. Start the engine. 5. Inspect for leaks. 6. Inspect the coolant level. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt Front Cover 89 in.lb Crankshaft Position Sensor Stud Side of Engine Block 98 in.lb Crankshaft Position Sensor Wiring Bracket Bolt 37 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 4169 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 4170 Locations View Crankshaft Position (24X) Sensor RH side of the engine, at the end of the crankshaft, behind the harmonic balancer. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 4171 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4174 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4175 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4176 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4177 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4178 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4179 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4180 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4181 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4182 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4183 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4184 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4185 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4186 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4187 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4188 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4189 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4190 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4191 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4192 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4193 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4194 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4195 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4196 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4197 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4198 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4199 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4200 Crankshaft Position Sensor (24X) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 7X Crankshaft Position (CKP) Sensor Crankshaft Position Sensor: Description and Operation 7X Crankshaft Position (CKP) Sensor The 7X crankshaft position sensor provides a signal used by the ignition control module. The ignition control module also uses the 7X crankshaft position sensor to generate 3X reference pulses which the PCM uses to calculate RPM and crankshaft position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 7X Crankshaft Position (CKP) Sensor > Page 4203 Crankshaft Position Sensor: Description and Operation 24X Crankshaft Position (CKP) Sensor 24X Crankshaft Position (CKP) Sensor The 24X crankshaft position (CKP) sensor (1) is used to improve idle spark control at engine speeds up to approximately 1600 RPM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure The Crankshaft Position System Variation compensating values are stored in the PCM non-volatile memory after a learn procedure has been performed. If the actual Crankshaft Position System Variation is not within the Crankshaft Position System Variation compensating values stored in the PCM, DTC P0300 may set. Refer to Diagnostic Aids for DTC P0300. The Crankshaft Position System Variation Learn Procedure should be performed if any of the following conditions are true: ^DTC P1336 is set. ^ The PCM has been replaced. ^ The engine has been replaced. ^ The crankshaft has been replaced. ^ The crankshaft harmonic balancer has been replaced. ^ The crankshaft position sensor has been replaced. Important: The scan tool Crankshaft Position System Variation Learn function will be inhibited if engine coolant temperature is less than 70°C (158°F). Allow the engine to warm to at least 70°C (158°F) before attempting the Crankshaft Position System Variation Learn Procedure. The scan tool Crankshaft Position System Variation Learn function will be inhibited if any Powertrain DTCs other than DTC P1336 are set before or during the Crankshaft Position System Variation Learn Procedure. Diagnose and repair any DTCs if set. Refer to applicable DTCs. The Crankshaft Position System Variation Learn function will be inhibited if the PCM detects a malfunction involving the camshaft position signal circuit, the 3X reference circuit, or the 24X reference circuit. If a malfunction has been indicated, refer to the following list to diagnose the system or sensor. ^ DTC P0336 Crankshaft Position (CKP) Sensor Circuit. ^ DTC P0341 Camshaft Position (CMP) Sensor Performance. ^ DTC P1374 Crankshaft Position (CKP) High to Low Resolution Frequency Correlation. The scan tool Crankshaft Position System Variation Learn function will not be enabled until engine coolant temperature reaches 70°C (158°F) Selecting the crankshaft position system variation learn procedure on the scan tool will command the PCM to enable CKP system variation learn fuel cutoff and allow the crankshaft position system variation compensating values to be stored in the PCM. The PCM must detect an engine speed of 5150 RPM (CKP system variation learn fuel cutoff) during the Crankshaft Position System Variation Learn Procedure to store the crankshaft position system variation compensating values and complete the procedure. Important: Block the drive wheels when performing the Crankshaft Position System Variation Learning Procedure in order to prevent personal injury. Set the vehicle parking brake when instructed by the scan tool. Quickly increase the accelerator pedal until wide open throttle is reached and hold. During the learn procedure the PCM will automatically control injector operation, when the RPM has reached a certain RPM the PCM will stop the fuel injectors from pulsing until the learn procedure is finished. When the PCM has learned the crankshaft variation the fuel injectors will return to normal operation and the engine will begin to accelerate again. Release the throttle when the engine reaches the second fuel cut off. Leaving the throttle open during the fuel cut off learn procedure will allow the engine to decel at an even rate. 1. Block the drive wheels. 2. Ensure the hood is closed. 3. Start the engine and allow engine coolant temperature to reach at least 70°C (158°F) 4. Turn OFF the ignition. 5. Select and enable the Crankshaft Position System Variation Learn Procedure with the scan tool. 6. Set the parking brake when instructed by the scan tool. 7. Start the vehicle. 8. Apply and hold the service brake pedal firmly. 9. Ensure the transaxle is in park. 10. Steadily increase the accelerator pedal until the fuel cutoff is reached at 5150 RPM and hold. Release the accelerator pedal after the second fuel cutoff has been reached. 11. The crankshaft position system variation compensating values are learned when the RPM decreases back to idle. If the procedure terminates. 12. Observe DTC status for DTC P1336. 13. If the scan tool indicates that DTC P1336 ran and passed, the Crankshaft Position System Variation Learn Procedure is complete. If the scan tool indicates DTC P1336 failed or not run, determine if other DTCs have set. If DTCs other than P1336 are not set, repeat the Crankshaft Position System Variation Learn Procedure as necessary. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 4206 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement (7X) REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Crank steering wheel fully to the left. 3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting. 4. Remove the right tire and wheel. 5. Disconnect the sensor electrical connector. 6. Remove the attaching bolt/screw. 7. Remove the sensor from engine. 8, Inspect for wear, cracks, or leakage if the sensor is not being replaced. INSTALLATION PROCEDURE 1. Lubricate the O-ring with clean engine oil before installation and replace if damaged. 2. Install the sensor to the block. 3. Reinstall the sensor attaching bolt. Tighten Tighten the bolt to 11 N.m (97 lb in). 4. Connect the sensor electrical connector. 5. Install the right tire and wheel. 6. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 4207 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement (24X) REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the serpentine drive belt from crankshaft pulley. 3. Raise the vehicle on hoist. Refer to Lifting and Jacking the Vehicle in General Information 4. Remove the crankshaft harmonic balancer. 5. Note the routing of sensor harness before removal. 6. Remove the harness retaining clip with bolt (1). 7. Disconnect the sensor electrical connector. 8, Remove the sensor bolts (4). 9. Remove the sensor. INSTALLATION PROCEDURE 1. Install the 24X crankshaft position sensor with bolts (4) and route harness as noted during removal. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the harness retaining clip with bolt (3). Tighten Tighten the bolts to 10 N.m (88 lb in). 3. Connect the sensor electrical connector. 4. Reinstall the balancer on the crankshaft. 5. Lower vehicle. 6. Reinstall the serpentine drive belt. 7. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Description and Operation EGR Valve Position Sensor: Description and Operation The Exhaust Gas Recirculation (EGR) pintle position sensor is an integral part of the EGR valve assembly. This sensor can not be serviced separately from the EGR valve assembly. EGR Pintle Position Sensor The PCM monitors the EGR valve pintle position input to ensure that the valve responds properly to commands from the PCM and to detect a fault if the pintle position sensor and control circuits are open or shorted. If the PCM detects a pintle position signal voltage outside the normal range of the pintle position sensor, or a signal voltage that is not within a tolerance considered acceptable for proper EGR system operation, the PCM will set DTC P1404 EGR valve stuck open. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Mounted in the fuel tank. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 4214 Fuel Level Sensor: Description and Operation The fuel level sensor consists of the following components: float, the wire float arm, and the ceramic resistor card. The fuel level sensor is mounted on the modular fuel sender assembly and is used as an input to the PCM. The PCM uses this information as a fuel level input for Various diagnostics. In addition the PCM transmits the fuel level over the Class II communication circuit to the IP cluster. This information is used for the IP fuel gauge, and low fuel warning indicator if applicable. Fuel Level Sensor The Fuel Level Sensor(4) is mounted on the Modular Fuel Sender Assembly(s). The PCM uses the fuel level input for various diagnosis including the EVAP System. In addition the PCM transmits the fuel level over the Class II communication circuit to the IP Cluster. The low fuel level message may not appear if other messages are being commanded, such as the rear deck lid, driver or passenger doors ajar. Ensure that all doors and compartment lids are completely closed. For further information regarding the Fuel Level Sensor refer to Fuel Metering Modes of Operation. See: Fuel Delivery and Air Induction/Description and Operation/Fuel Metering/Fuel Metering Modes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 4215 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure. See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair 2. Remove the modular fuel sender assembly. 3. Remove the fuel level sensor (5) from the modular fuel sender. INSTALLATION PROCEDURE 1. Reinstall the fuel level sensor (5) to modular fuel sender. 2. Reinstall the fuel sender assembly. 3. Tighten the fuel filler cap. 4. Reconnect the negative battery cable. 5. Inspect for fuel leaks. 5.1. Turn the ignition ON for 2 seconds 5.2. Turn the ignition OFF for 10 seconds. 5.3. Turn the ignition ON. 5.4. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Fuel Tank Pressure (FTP) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Fuel Tank Pressure Sensor - 1 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor - 1 The Fuel Tank Pressure (FTP) sensor measures the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The sensor mounts at the top of the fuel tank sending unit. The PCM supplies a 5 volt reference voltage and ground to the sensor. The sensor provides a signal voltage between 0.1-4.9 volts to the PCM. When the air pressure in the fuel tank is equal to the outside air pressure, such as when the fuel fill cap is removed, the output voltage of the sensor will measure 1.3-1.7 volts. When the air pressure in the tank is 4.5 inches H20 (1.25 kPa), the sensor output voltage should measure 0.5 ± 0.2 volts (1.25 kPa). The sensor voltage increases to approximately 4.5 volts at 14 inches of H2O (-3.75 kpa). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Fuel Tank Pressure Sensor - 1 > Page 4221 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor - 2 Fuel Tank Pressure Sensor The Fuel Tank Pressure Sensor(6) is mounted on top the Modular Fuel Sender Assembly(S). The PCM uses the fuel tank pressure input for the EVAP System. The PCM supplies a 5 volt reference to the sensor and a sensor return (ground). The PCM monitors the signal circuit from the sensor with a voltage range from 0.1 volts to 4.9 volts. When the pressure inside the fuel tank is totally vented the pressure is equal to atmospheric pressure or approximately 1.3-1.7 volts. When the tank is pressurized the voltage can reach more than 4.5 volts. For further information regarding the Fuel Tank Pressure Sensor refer to Fuel Metering Modes of Operation, and EVAP Control System Operation Description. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Fuel Tank Pressure Sensor - 1 > Page 4222 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor - 3 Fuel Tank Pressure Sensor The Fuel Tank Pressure (FTP) sensor measures the difference between the air pressure, or vacuum, in the fuel tank and the outside air pressure. The sensor mounts at the top of the fuel tank sending unit. The PCM supplies a 5 volt reference voltage and ground to the sensor. The sensor provides a signal voltage between 0.1-4.9 volts to the PCM. When the air pressure in the fuel tank is equal to the outside air pressure, such as when the fuel fill cap is removed, the output voltage of the sensor will measure 1.3-1.7 volts. When the air pressure in the tank is 1.25 kPa (4.5 inches Hg), the sensor output voltage should measure 1.25 kPa (approx 0.5 volts). The sensor voltage increases to approximately 4.5 volts at -3.75 kPa (14 inches of Hg). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 4223 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the spare tire cover, the jack, and the spare tire. 3. Remove the trunk liner. 4. Remove the 7 nuts retaining the fuel sender access panel. 5. Remove the fuel sender access panel. 6. Disconnect the electrical connector from the fuel tank vapor pressure sensor. 7. Remove the fuel tank vapor pressure sensor (7) from modular fuel sender assembly. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 4224 1. Reinstall the new fuel tank vapor pressure sensor (7) to modular fuel sender. 2. Connect the electrical connector to fuel tank vapor pressure sensor 3. Reinstall the fuel sender access panel. 4. Reinstall the 7 nuts retaining the fuel sender access panel. Tighten Tighten the fuel sender access panel nuts to 10 N.m (88 lb in) 5. Reinstall the trunk liner. 6. Reinstall the spare tire, the jack, and the spare tire cover. 7. Reconnect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Intake Air Temperature (IAT) Sensor: Locations Intake Air Temperature (IAT) Sensor is in the air induction tube. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions Intake Air Temperature (IAT) Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4230 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4231 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4232 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4233 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4234 Intake Air Temperature (IAT) Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4235 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4236 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4237 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4238 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4239 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4240 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4241 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4242 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4243 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4244 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4245 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4246 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4247 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4248 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4249 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4250 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4251 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4252 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4253 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4254 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4255 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4256 Intake Air Temperature Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4257 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Page 4258 Intake Air Temperature (IAT) Sensor: Description and Operation The Intake Air Temperature (IAT) sensor is a thermistor which changes value based on the temperature of air entering the engine. Low temperature produces a high resistance (100,000 ohms at -40°C/-40°F), while high temperature causes low resistance (70 ohms at 130°C/266°F). The PCM supplies a 5.0 volt signal to the sensor through a resistor in the PCM and measures the voltage. The voltage will be high when the incoming air is cold, and low when the air is hot. By measuring the voltage, the PCM calculates the incoming air temperature. The IAT sensor signal is used to adjust spark timing according to incoming air density. The scan tool displays temperature of the air entering the engine, which should read close to ambient air temperature when the engine is cold, and rise as the underhood temperature increases. If the engine has not been run for several hours (overnight) the IAT sensor temperature and engine coolant temperature should read close to each other. A failure in the IAT sensor circuit should set DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage or DTC P0113 Intake Air Temperature (IAT) Sensor Circuit High Voltage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Page 4259 Intake Air Temperature (IAT) Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the IAT sensor electrical connector. 3. Carefully grasp the sensor and with a twisting and pulling motion, remove the IAT sensor from air intake duct. INSTALLATION PROCEDURE 1. Install the IAT sensor (snap into place). 2. Connect the IAT sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications knock Sensor 19 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations Knock Sensor: Component Locations Left Front Of Engine Knock Sensor (KS) Bank 1 Lower RR of the engine, below the exhaust manifold. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations > Page 4265 Knock Sensor: Connector Locations Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations > Page 4266 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4269 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4270 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4271 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4272 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4273 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4274 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4275 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4276 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4277 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4278 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4279 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4280 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4281 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4282 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4283 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4284 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4285 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4286 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4287 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4288 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4289 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4290 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4291 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4292 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4293 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4294 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4295 Knock Sensor (KS) 1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4296 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > General Information Knock Sensor: Description and Operation General Information The knock sensor detects abnormal vibration (spark knocking) in the engine. The sensor is located on the engine block near the cylinders. The sensor produces an AC output voltage which increases with the severity of the knock. This signal voltage is input to the PCM. The PCM then adjusts the Ignition Control (IC) timing to reduce spark knock. DTC P0325 Knock Sensor (KS) Circuit DTC P0327 Knock Sensor (KS) Circuit are designed to diagnose the PCM, the knock sensor, and related wiring, so problems encountered with the KS system should set a DTC. Refer to Knock Sensor (KS) System Description description of the knock sensor system. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > General Information > Page 4299 Knock Sensor: Description and Operation Operation The knock sensor detects abnormal vibration (spark knocking) in the engine. The knock sensor is mounted in the engine block near the cylinders and produce an AC signal under all engine operating conditions. The PCM contains integrated Knock Sensor (KS) diagnostic circuitry which uses the input signals from the knock sensors to detect engine detonation. This allows the PCM to retard Ignition Control (IC) spark timing based on the amplitude and frequency of the KS signal being received. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > General Information > Page 4300 Knock Sensor: Description and Operation Purpose Knock Sensor (KS) System Description Purpose Varying octane levels in todays gasoline may cause detonation in some engines. Detonation is caused by an uncontrolled explosion (burn) in the combustion chamber. This uncontrolled explosion could produce a flame front opposite that of the normal flame front produced by the spark plug. The rattling sound normally associated with detonation is the result of two or more opposing pressures (flame fronts) colliding within the combustion chamber. Though light detonation is sometimes considered normal, heavy detonation could result in engine damage. To control spark knock, a Knock Sensor (KS) system is used. This system is designed to retard spark timing when spark knock is detected in the engine. The KS system allows the engine to use maximum spark advance for optimal driveability and fuel economy. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 4301 Knock Sensor: Testing and Inspection The PCM calculates an average voltage the knock sensor signal and takes instantaneous signal voltage readings. The PCM uses the instantaneous signal voltage reading to determine the state of the knock sensor circuitry. If the knock sensor system is operating normally, the PCM should monitor instantaneous KS signal voltage readings varying outside a voltage range above and below the calculated average voltage. The following DTCs are used to diagnose the knock sensor system: ^ If the PCM malfunctions in a manner which will not allow proper diagnosis of the KS circuits, DTC P0325 will set. ^ DTC P0327 is designed to diagnose the knock sensor, and related wiring, so problems encountered with the KS system should set a DTC. However, if no DTC was set but the KS system is suspect because detonation was the customer's complaint, use the tables for P0327 to diagnose the Detonation/Spark Knock Symptom. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 4302 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting. 3. Disconnect the knock sensor wiring harness connector from the knock sensor. 4. Remove the knock sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Do Not apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. NOTE: Refer to Fastener Notice in Service Precautions. Knock Sensor (KS) System Deascription Purpose 1. Install the knock sensor into engine block. Tighten Tighten the knock sensor to 19 N.m (14 lb ft). 2. Connect the knock sensor wiring harness connector to the knock sensor. 3. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications Manifold Absolute Pressure (MAP) Sensor: Specifications Manifold Absolute Pressure (MAP) Sensor Retaining Bolt 3 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 4306 Manifold Absolute Pressure (MAP) Sensor: Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 4307 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions Manifold Absolute Pressure (MAP) Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4310 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4311 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4312 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4313 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4314 Manifold Absolute Pressure (MAP) Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4315 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4316 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4317 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4318 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4319 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4320 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4321 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4322 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4323 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4324 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4325 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4326 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4327 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4328 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4329 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4330 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4331 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4332 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4333 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4334 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4335 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4336 Manifold Air Pressure (MAP) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4337 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Page 4338 Manifold Absolute Pressure (MAP) Sensor: Description and Operation The Manifold Absolute Pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the PCM varies from below 2.0 volts at idle (high vacuum) to above 4.0 volts with the key ON, and the engine OFF, or at wide open throttle (low vacuum). The MAP sensor is used to determine manifold pressure changes while the linear EGR flow test diagnostic is being run, Refer to DTC P0401 Exhaust Gas Recirculation (EGR) Flow Insufficient, to determine engine vacuum level for other diagnostics and to determine Barometric Pressure (BARO). If the PCM detects a voltage that is lower than the possible range of the MAP sensor, DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage will be set. A signal voltage higher than the possible range of the sensor will set DTC P0108 Manifold Absolute Pressure (MAP) Sensor Circuit High Voltage. An intermittent low or high voltage will set DTC P1107 Manifold Absolute Pressure (MAP) Sensor Circuit Intermittent Low Voltage or DTC P1106 Manifold Absolute Pressure (MAP) Sensor Circuit Intermittent High Voltage respectively. The PCM can also detect a shifted MAP sensor. The PCM compares the MAP sensor signal to a calculated MAP based on throttle position and various engine load factors Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Page 4339 Manifold Absolute Pressure (MAP) Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the MAP sensor from the bracket. 2. Disconnect the MAP inlet vacuum hose. 3. Disconnect the MAP sensor electrical connector. INSTALLATION PROCEDURE 1. Connect the MAP sensor electrical connector. 2. Connect the inlet vacuum hose. 3. Position the MAP sensor to bracket and tighten fasteners. Tighten Tighten the MAP sensor fasteners to 3 N.m (27 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations Oil Level Sensor For ECM: Locations Front center of the engine oil pan. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 4343 Engine Oil Level Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 4347 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Heated Oxygen Sensors 41 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4353 Locations View Heated Oxygen Sensor 1 (HO2S1) Rear of the engine, in the exhaust manifold. Heated Oxygen Sensor 2 (HO2A2) In the exhaust system, behind the catalytic converter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4354 Oxygen Sensor: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4355 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4358 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4359 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4360 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4361 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4362 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4363 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4364 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4365 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4366 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4367 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4368 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4369 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4370 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4371 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4372 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4373 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4374 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4375 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4376 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4377 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4378 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4379 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4380 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4381 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4382 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4383 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4384 Oxygen Sensor: Connector Views Heated Oxygen Sensor (HO2S2) 1 Heated Oxygen Sensor (HO2S2) 2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4385 Oxygen Sensor: Electrical Diagrams Schematic Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Fuel Control Heated Oxygen Sensor (HO2S 1) Oxygen Sensor: Description and Operation Fuel Control Heated Oxygen Sensor (HO2S 1) Fuel Controlled Heated Oxygen Sensor (H02S 1) The fuel control Heated Oxygen Sensor (HO2S 1) is mounted in the exhaust manifold where it can monitor the oxygen content of the exhaust gas stream. The oxygen present in the exhaust gas reacts with the sensor to produce a voltage output. This voltage should constantly fluctuate from approximately 100 mV (high oxygen content lean mixture) to 900 mV (low oxygen content rich mixture). The heated oxygen sensor voltage can be monitored with a scan tool. By monitoring the voltage output of the oxygen sensor, the PCM calculates what fuel mixture command to give to the injectors (lean mixture low HO2S voltage = rich command, rich mixture high HO2S voltage = lean command). The HO2S 1 circuit, if open, should set a DTC P0134 HO2S Circuit Insufficient Activity Sensor 1 and the scan tool will display a constant voltage between 400-500 mV. A constant voltage below 300 mV in the sensor circuit (circuit grounded) should set DTC P0131 HO2S Circuit Low Voltage Sensor 1, while a constant voltage above 800 mV in the circuit should set DTC P0132 HO2S Circuit High Voltage Sensor 1. A fault in the HO2S 1 heater circuit should cause DTC P0135 to set. The PCM can also detect HO2S response problems. If the response time of an HO2S is determined to be too slow, the PCM will store a DTC that indicates degraded HO2S performance. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Fuel Control Heated Oxygen Sensor (HO2S 1) > Page 4388 Oxygen Sensor: Description and Operation Catalyst Monitor Heated Oxygen Sensor (HO2S 2) To control emissions of Hydrocarbons (HC), Carbon Monoxide (CO), and oxides of nitrogen (NOx), a three-way catalytic converter is used. The catalyst within the converter promotes a chemical reaction which oxidizes the HG and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The PCM has the ability to monitor this process using the HO2S 1 and the HO2S 2. The HO2S 1 produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The HO2S 2 produces an output signal which indicates the oxygen storage capacity of the catalyst, this in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the HO2S 1 signal will be far more active than that produced by the HO2S 2. The catalyst monitor sensors operate the same as the fuel control sensors. Although the HO2S 2 main function is catalyst monitoring, it also plays a limited role in fuel control. If the sensor output indicates a voltage either above or below the 450 millivolt bias voltage for an extended period of time, the PCM will make a slight adjustment to fuel trim to ensure that fuel delivery is correct for catalyst monitoring. A problem with the HO2S 2 signal circuit should set DTC P0137 HO2S Circuit Low Voltage Sensor 2, DTC P0138 HO2S Circuit High Voltage Sensor 2, or DTC P0140 HO2S Circuit Insufficient Activity Sensor 2, depending on the specific condition. A fault in the heated oxygen sensor heater element or its ignition feed or ground will result in slower oxygen sensor response. This may cause erroneous Catalyst monitor diagnostic results. A fault in the HO2S 2 heater circuit should cause DTC P0141 HO2S Heater Performance Sensor 2 to set. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement (HO2S1) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement (HO2S1) TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Socket REMOVAL PROCEDURE (HO2S1) The heated oxygen sensor may be difficult to remove when engine temperature is below 48°C (120°F). Excessive force may damage threads in exhaust manifold or exhaust pipe. 1. Turn OFF the ignition. 2. Disconnect the electrical connector. IMPORTANT: A special anti seize compound is used on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine and if for any reason is to be reinstalled, the threads must have anti seize compound applied before reinstallation. 3. Using J 39194-B heated oxygen sensor socket carefully back out the heated oxygen sensor. INSTALLATION PROCEDURE (HO2S1) 1. Coat the threads of heated oxygen sensor/catalyst monitor with anti seize compound P/N 5613695, or equivalent if necessary. 2. Install the heated oxygen sensor. Tighten Tighten the HO2S 1 (Pre-catalytic converter) to 41 N.m (30 lb ft). 3. Connect the HO2S1 sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement (HO2S1) > Page 4391 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement (HO2S2) TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Socket REMOVAL PROCEDURE (HO2S2) The heated oxygen sensor may be difficult to remove when engine temperature is below 48°C (120°F). Excessive force may damage threads in exhaust manifold or exhaust pipe. 1. Turn OFF the ignition. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting. 3. Disconnect the sensor electrical connector. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine and if for any reason is to be reinstalled, the threads must have anti seize compound applied before reinstallation. 4. Using J 39194-B heated oxygen sensor socket carefully back out the heated oxygen sensor. INSTALLATION PROCEDURE (HO2S2) 1. Coat the threads of heated oxygen sensor/catalyst monitor with anti seize compound PIN 5613695, or equivalent if necessary. NOTE: Refer to Fastener Notice in Service Precautions. 2. Using J 39194-B heated oxygen sensor socket install the heated oxygen sensor. Tighten Tighten the HO2S2 to 41 N.m (30 lb ft). 3. Connect the HO2S2 sensor electrical connector. 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screws 2 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4395 Throttle Position Sensor: Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4396 Left Front Of Engine Top of the engine, on the throttle body assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4399 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4400 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4401 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4402 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4403 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4404 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4405 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4406 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4407 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4408 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4409 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4410 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4411 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4412 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4413 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4414 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4415 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4416 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4417 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4418 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4419 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4420 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4421 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4422 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4423 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4424 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4425 Throttle Position Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 4426 Throttle Position Sensor: Description and Operation The Throttle Position (TP) sensor is a potentiometer connected to the throttle shaft on the throttle body. By monitoring the voltage on the signal line, the PCM calculates throttle position. As the throttle valve angle is changed (accelerator pedal moved), the TP sensor signal also changes. At a closed throttle position, the output of the TP sensor is low. As the throttle valve opens, the output increases so that at Wide Open Throttle (WOT), the output voltage should be above 4.0 volts. The PCM calculates fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor may cause intermittent bursts of fuel from an injector and unstable idle because the PCM thinks the throttle is moving. A hard failure in the TP sensor 5.0 volt reference or signal circuits should set either a DTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage. A hard failure with the TP Sensor ground circuit may set DTCs DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage, DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage, DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage, or DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage. Once a DTC is set, the PCM will use an artificial default value based on engine RPM, engine load and mass air flow for throttle position and some vehicle performance will return. A high idle may result when either DTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage, or DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage is set. The PCM can detect intermittent TP sensor faults. DTC P1121 Throttle Position (TP) Sensor Circuit Intermittent High Voltage, or DTC P 1122 Throttle Position (TP) Sensor Circuit Intermittent Low Voltage will set it an intermittent high or low circuit failure is being detected. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 4427 The PCM can also detect a shifted TP sensor (2). The PCM monitors throttle position and compares the actual TP sensor reading to a predicted TP value calculated from engine speed. If the PCM detects an out of range condition, DTC P0121 Throttle Position (TP) Sensor Performance will be set. The non-adjustable TP sensor is mounted on the side of the throttle body opposite the throttle lever. It senses the throttle valve angle and relays that information to the PCM. Knowledge of the throttle angle is needed by the PCM to generate the required injector control signals (pulse). For further information, Refer to Information Sensors/Switches Description. See: Computers and Control Systems/Description and Operation/Information Sensors/Switches Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 4428 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the TP sensor electrical connector. 3. Remove the 2 TP sensor attaching screws. 4. Remove the TP sensor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 4429 5. Remove the TP sensor O-ring. INSTALLATION PROCEDURE 1. Install the TP sensor O-ring. 2. With the throttle valve in the normal closed idle position, install the TP sensor on the throttle body assembly. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 4430 3. Reinstall the 2 TP sensor attaching screws, using a thread-locking compound on the screws. Loctite (R) 262, GM P/N 1052624, or equivalent should be used. Tighten Tighten the TP sensor attaching screws to 2.0 N.m (18 lb in). 4. Connect the TP sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Inside the automatic transaxle Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4434 Park Neutral Position (PNP) Switch C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Speed Sensor to Case 106 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 4438 Vehicle Speed Sensor: Locations Locations View RR of the engine, on the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4441 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4442 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4443 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4444 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4445 Vehicle Speed Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4446 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4447 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4448 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4449 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4450 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4451 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4452 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4453 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4454 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4455 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4456 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4457 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4458 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4459 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4460 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4461 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4462 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4463 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4464 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4465 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4466 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4467 Vehicle Speed Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4468 Vehicle Speed Sensor: Service and Repair Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment 3. Remove the vehicle speed sensor wiring harness connector. 4. Remove the vehicle speed sensor bolt (9). 5. Remove the vehicle speed sensor (10) from the extension case. 6. Remove the O-ring (11) from the vehicle speed sensor(10). Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4469 1. Install the O-ring (111) to the vehicle speed sensor (10). 2. Install the vehicle speed sensor (10) to the extension case. Notice: Refer to Fastener Notice in Service Precautions 3. Install the vehicle speed sensor bolt (9). - Tighten the vehicle speed sensor bolt (9) to 12 Nm (106 inch lbs.). 4. Install the vehicle speed sensor wiring harness connector. 5. Install the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment 6. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Description and Operation EGR Valve Position Sensor: Description and Operation The Exhaust Gas Recirculation (EGR) pintle position sensor is an integral part of the EGR valve assembly. This sensor can not be serviced separately from the EGR valve assembly. EGR Pintle Position Sensor The PCM monitors the EGR valve pintle position input to ensure that the valve responds properly to commands from the PCM and to detect a fault if the pintle position sensor and control circuits are open or shorted. If the PCM detects a pintle position signal voltage outside the normal range of the pintle position sensor, or a signal voltage that is not within a tolerance considered acceptable for proper EGR system operation, the PCM will set DTC P1404 EGR valve stuck open. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations LF of the engine compartment, in the air cleaner duct. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions Mass Air Flow (MAF) Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4480 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4481 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4482 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4483 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4484 Mass Air Flow (MAF) Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4485 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4486 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4487 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4488 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4489 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4490 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4491 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4492 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4493 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4494 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4495 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4496 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4497 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4498 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4499 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4500 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4501 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4502 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4503 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4504 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4505 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4506 Mass Air Flow (MAF) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4507 Mass Air Flow (MAF) Sensor: Electrical Diagrams Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4508 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Page 4509 Mass Air Flow (MAF) Sensor: Description and Operation The Mass Air Flow (MAF) sensor measures the amount of air which passes through it. The PCM uses this information to determine the operating condition of the engine, to control fuel delivery. A large quantity of air indicates acceleration, while a small quantity indicates deceleration or idle. The scan tool reads the MAF value and displays it in grams per second (gm/s). At idle, it should read between 4 gm/s to 6 gm/s on a fully warmed up engine. Values should change rather quickly on acceleration, but values should remain fairly stable at any given RPM. A failure in the MAF sensor or circuit should set DTC P0101 Mass Air Flow (MAF) Sensor Performance, DTC P0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency, or DTC P0103 Mass Air Flow (MAF) Sensor Circuit High Frequency The MAF sensor is attached to the front (air inlet side) of the throttle body and is used to measure the amount of air entering the engine. The PCM uses this information to determine the operating condition of the engine and to control fuel delivery. For further information, refer to Information Sensors/Switches Description. See: Computers and Control Systems/Description and Operation/Information Sensors/Switches Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Page 4510 Mass Air Flow (MAF) Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the MAF sensor (1) electrical connector. 4. Remove the air inlet duct from the MAF sensor and the throttle body. 5. Remove the MAF sensor from the air filter housing. INSTALLATION PROCEDURE 1. Install the MAF sensor to the air filter housing. 2. Install the air inlet duct to the MAF sensor and throttle body. 3. Connect the IAT sensor (1) electrical connector. 4. Connect the MAF sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Component Locations Oil Pressure Switch (For Fuel Pump): Component Locations Engine Oil Pressure Indicator Switch (LA1) Front of the engine, above the starter. RPO LA1: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Engine Oil Pressure Indicator Switch (L36) Near generator. RPO L36: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Component Locations > Page 4515 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Component Locations > Page 4516 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 4517 Oil Pressure Switch (For Fuel Pump): Description and Operation Engine Oil Pressure Switch The PCM monitors the engine oil pressure switch (1) signal to determine if the engine oil pressure is OK. If the PCM determines that a low oil pressure condition exists, the PCM will communicate the information over the Class II circuit to the P cluster and it will illuminate the indicator lamp or initiate a message. The low oil pressure message may not appear if other messages are being commanded, such as the rear deck lid, driver or passenger doors ajar. Ensure that all doors and compartment lids are completely closed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screws 2 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 4521 Throttle Position Sensor: Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 4522 Left Front Of Engine Top of the engine, on the throttle body assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4525 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4526 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4527 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4528 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4529 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4530 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4531 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4532 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4533 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4534 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4535 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4536 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4537 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4538 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4539 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4540 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4541 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4542 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4543 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4544 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4545 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4546 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4547 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4548 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4549 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4550 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4551 Throttle Position Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 4552 Throttle Position Sensor: Description and Operation The Throttle Position (TP) sensor is a potentiometer connected to the throttle shaft on the throttle body. By monitoring the voltage on the signal line, the PCM calculates throttle position. As the throttle valve angle is changed (accelerator pedal moved), the TP sensor signal also changes. At a closed throttle position, the output of the TP sensor is low. As the throttle valve opens, the output increases so that at Wide Open Throttle (WOT), the output voltage should be above 4.0 volts. The PCM calculates fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor may cause intermittent bursts of fuel from an injector and unstable idle because the PCM thinks the throttle is moving. A hard failure in the TP sensor 5.0 volt reference or signal circuits should set either a DTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage. A hard failure with the TP Sensor ground circuit may set DTCs DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage, DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage, DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage, or DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage. Once a DTC is set, the PCM will use an artificial default value based on engine RPM, engine load and mass air flow for throttle position and some vehicle performance will return. A high idle may result when either DTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage, or DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage is set. The PCM can detect intermittent TP sensor faults. DTC P1121 Throttle Position (TP) Sensor Circuit Intermittent High Voltage, or DTC P 1122 Throttle Position (TP) Sensor Circuit Intermittent Low Voltage will set it an intermittent high or low circuit failure is being detected. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 4553 The PCM can also detect a shifted TP sensor (2). The PCM monitors throttle position and compares the actual TP sensor reading to a predicted TP value calculated from engine speed. If the PCM detects an out of range condition, DTC P0121 Throttle Position (TP) Sensor Performance will be set. The non-adjustable TP sensor is mounted on the side of the throttle body opposite the throttle lever. It senses the throttle valve angle and relays that information to the PCM. Knowledge of the throttle angle is needed by the PCM to generate the required injector control signals (pulse). For further information, Refer to Information Sensors/Switches Description. See: Computers and Control Systems/Description and Operation/Information Sensors/Switches Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 4554 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the TP sensor electrical connector. 3. Remove the 2 TP sensor attaching screws. 4. Remove the TP sensor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 4555 5. Remove the TP sensor O-ring. INSTALLATION PROCEDURE 1. Install the TP sensor O-ring. 2. With the throttle valve in the normal closed idle position, install the TP sensor on the throttle body assembly. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 4556 3. Reinstall the 2 TP sensor attaching screws, using a thread-locking compound on the screws. Loctite (R) 262, GM P/N 1052624, or equivalent should be used. Tighten Tighten the TP sensor attaching screws to 2.0 N.m (18 lb in). 4. Connect the TP sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 89 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations RH side of the engine, below the intake plenum. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 4563 Camshaft Position Sensor: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 4564 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4567 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4568 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4569 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4570 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4571 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4572 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4573 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4574 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4575 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4576 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4577 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4578 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4579 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4580 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4581 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4582 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4583 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4584 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4585 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4586 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4587 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4588 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4589 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4590 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4591 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4592 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4593 Camshaft Position Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position (CMP) Sensor and Cam Signal Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor and Cam Signal The camshaft position sensor sends a cam signal to the PCM which uses it as a sync pulse to trigger the injectors in proper sequence. The PCM uses the CAM signal to indicate the position of the #1 piston during its intake stroke. This allows the PCM to calculate true Sequential Fuel Injection (SFI) mode of operation. If the PCM detects an incorrect CAM signal while the engine is running, DTC P0341 Camshaft Position (CMP) Sensor Performance will set. If the CAM signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection mode based on the last fuel injection pulse, and the engine will continue to run. The engine can be restarted and will run in the calculated sequential mode as long as the fault is present with a 1 in 6 chance of injector sequence being correct. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position (CMP) Sensor and Cam Signal > Page 4596 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The camshaft position sensor is located on the timing cover behind the water pump near the camshaft sprocket. As the camshaft sprocket turns, a magnet in it activates the Hall-effect switch in the camshaft position sensor. When the Hall-effect switch is activated, it grounds the signal line to the PCM, pulling the camshaft position sensor signal circuit's applied voltage low. This is interpreted as a CAM signal. The CAM signal is created as piston #1 is on the intake stroke. If the correct CAM signal is not received by the PCM, DTC P0341 will be set. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 4597 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the serpentine drive belt. 3. Loosen the power steering pump to gain access to the CMP. 4. Disconnect the sensor electrical connector. 5. Remove the attaching bolt. 6. Remove the sensor. 7. Inspect the sensor for wear, cracks or leakage if the sensor is not being replaced. INSTALLATION PROCEDURE 1. Lubricate the O-ring with clean engine oil and replace if damaged. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the camshaft position sensor. Tighten Tighten the retaining bolt to 10 N.m (88 lb in). 3. Connect the sensor electrical connector. 4. Install the power steering pump. 5. Reinstall the serpentine drive belt. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt Front Cover 89 in.lb Crankshaft Position Sensor Stud Side of Engine Block 98 in.lb Crankshaft Position Sensor Wiring Bracket Bolt 37 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 4603 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 4604 Locations View Crankshaft Position (24X) Sensor RH side of the engine, at the end of the crankshaft, behind the harmonic balancer. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 4605 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4608 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4609 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4610 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4611 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4612 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4613 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4614 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4615 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4616 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4617 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4618 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4619 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4620 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4621 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4622 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4623 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4624 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4625 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4626 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4627 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4628 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4629 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4630 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4631 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4632 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4633 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4634 Crankshaft Position Sensor (24X) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 7X Crankshaft Position (CKP) Sensor Crankshaft Position Sensor: Description and Operation 7X Crankshaft Position (CKP) Sensor The 7X crankshaft position sensor provides a signal used by the ignition control module. The ignition control module also uses the 7X crankshaft position sensor to generate 3X reference pulses which the PCM uses to calculate RPM and crankshaft position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 7X Crankshaft Position (CKP) Sensor > Page 4637 Crankshaft Position Sensor: Description and Operation 24X Crankshaft Position (CKP) Sensor 24X Crankshaft Position (CKP) Sensor The 24X crankshaft position (CKP) sensor (1) is used to improve idle spark control at engine speeds up to approximately 1600 RPM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure The Crankshaft Position System Variation compensating values are stored in the PCM non-volatile memory after a learn procedure has been performed. If the actual Crankshaft Position System Variation is not within the Crankshaft Position System Variation compensating values stored in the PCM, DTC P0300 may set. Refer to Diagnostic Aids for DTC P0300. The Crankshaft Position System Variation Learn Procedure should be performed if any of the following conditions are true: ^DTC P1336 is set. ^ The PCM has been replaced. ^ The engine has been replaced. ^ The crankshaft has been replaced. ^ The crankshaft harmonic balancer has been replaced. ^ The crankshaft position sensor has been replaced. Important: The scan tool Crankshaft Position System Variation Learn function will be inhibited if engine coolant temperature is less than 70°C (158°F). Allow the engine to warm to at least 70°C (158°F) before attempting the Crankshaft Position System Variation Learn Procedure. The scan tool Crankshaft Position System Variation Learn function will be inhibited if any Powertrain DTCs other than DTC P1336 are set before or during the Crankshaft Position System Variation Learn Procedure. Diagnose and repair any DTCs if set. Refer to applicable DTCs. The Crankshaft Position System Variation Learn function will be inhibited if the PCM detects a malfunction involving the camshaft position signal circuit, the 3X reference circuit, or the 24X reference circuit. If a malfunction has been indicated, refer to the following list to diagnose the system or sensor. ^ DTC P0336 Crankshaft Position (CKP) Sensor Circuit. ^ DTC P0341 Camshaft Position (CMP) Sensor Performance. ^ DTC P1374 Crankshaft Position (CKP) High to Low Resolution Frequency Correlation. The scan tool Crankshaft Position System Variation Learn function will not be enabled until engine coolant temperature reaches 70°C (158°F) Selecting the crankshaft position system variation learn procedure on the scan tool will command the PCM to enable CKP system variation learn fuel cutoff and allow the crankshaft position system variation compensating values to be stored in the PCM. The PCM must detect an engine speed of 5150 RPM (CKP system variation learn fuel cutoff) during the Crankshaft Position System Variation Learn Procedure to store the crankshaft position system variation compensating values and complete the procedure. Important: Block the drive wheels when performing the Crankshaft Position System Variation Learning Procedure in order to prevent personal injury. Set the vehicle parking brake when instructed by the scan tool. Quickly increase the accelerator pedal until wide open throttle is reached and hold. During the learn procedure the PCM will automatically control injector operation, when the RPM has reached a certain RPM the PCM will stop the fuel injectors from pulsing until the learn procedure is finished. When the PCM has learned the crankshaft variation the fuel injectors will return to normal operation and the engine will begin to accelerate again. Release the throttle when the engine reaches the second fuel cut off. Leaving the throttle open during the fuel cut off learn procedure will allow the engine to decel at an even rate. 1. Block the drive wheels. 2. Ensure the hood is closed. 3. Start the engine and allow engine coolant temperature to reach at least 70°C (158°F) 4. Turn OFF the ignition. 5. Select and enable the Crankshaft Position System Variation Learn Procedure with the scan tool. 6. Set the parking brake when instructed by the scan tool. 7. Start the vehicle. 8. Apply and hold the service brake pedal firmly. 9. Ensure the transaxle is in park. 10. Steadily increase the accelerator pedal until the fuel cutoff is reached at 5150 RPM and hold. Release the accelerator pedal after the second fuel cutoff has been reached. 11. The crankshaft position system variation compensating values are learned when the RPM decreases back to idle. If the procedure terminates. 12. Observe DTC status for DTC P1336. 13. If the scan tool indicates that DTC P1336 ran and passed, the Crankshaft Position System Variation Learn Procedure is complete. If the scan tool indicates DTC P1336 failed or not run, determine if other DTCs have set. If DTCs other than P1336 are not set, repeat the Crankshaft Position System Variation Learn Procedure as necessary. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 4640 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement (7X) REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Crank steering wheel fully to the left. 3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting. 4. Remove the right tire and wheel. 5. Disconnect the sensor electrical connector. 6. Remove the attaching bolt/screw. 7. Remove the sensor from engine. 8, Inspect for wear, cracks, or leakage if the sensor is not being replaced. INSTALLATION PROCEDURE 1. Lubricate the O-ring with clean engine oil before installation and replace if damaged. 2. Install the sensor to the block. 3. Reinstall the sensor attaching bolt. Tighten Tighten the bolt to 11 N.m (97 lb in). 4. Connect the sensor electrical connector. 5. Install the right tire and wheel. 6. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 4641 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement (24X) REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the serpentine drive belt from crankshaft pulley. 3. Raise the vehicle on hoist. Refer to Lifting and Jacking the Vehicle in General Information 4. Remove the crankshaft harmonic balancer. 5. Note the routing of sensor harness before removal. 6. Remove the harness retaining clip with bolt (1). 7. Disconnect the sensor electrical connector. 8, Remove the sensor bolts (4). 9. Remove the sensor. INSTALLATION PROCEDURE 1. Install the 24X crankshaft position sensor with bolts (4) and route harness as noted during removal. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the harness retaining clip with bolt (3). Tighten Tighten the bolts to 10 N.m (88 lb in). 3. Connect the sensor electrical connector. 4. Reinstall the balancer on the crankshaft. 5. Lower vehicle. 6. Reinstall the serpentine drive belt. 7. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Switch Lock Cylinder - Dash Mounted Ignition Switch Lock Cylinder: Service and Repair Ignition Switch Lock Cylinder - Dash Mounted IGNITION SWITCH LOCK CYLINDER REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the body control module (BCM) theft deterrent relearn procedure whenever you replace the ignition switch lock cylinder. See: Computers and Control Systems/Body Control Module/Service and Repair/Procedures/Body Control Module (BCM) Programming/RPO Configuration 1. Disconnect the negative battery cable. 2. Remove the instrument panel (I/P) cluster trim plate. 3. Insert the key and turn the ignition lock cylinder to the ON/RUN position. 4. Using a small curved tool or an L-shaped hex wrench, depress and hold the detent on the ignition lock cylinder. Access the detent by placing the tool through the I/P opening to the right of the ignition switch. If you cannot locate the detent with the tool, lower the ignition switch away from the I/P. Refer to Ignition Switch Replacement. 5. Using the key as an aid, pull to remove the lock cylinder from the switch. 6. Remove the key from the lock cylinder. 7. If the cylinder does not rotate or is seized, follow the procedure in the ignition switch replacement. Refer to Ignition Switch Replacement. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Switch Lock Cylinder - Dash Mounted > Page 4647 1. Code the ignition lock cylinder, if necessary. Refer to Key and Lock Cylinder Coding. 2. Insert the key and turn the lock cylinder to the ON/RUN position. 3. Position the lock cylinder to the ignition switch. Press the cylinder into place. If you turned the key slightly while removing the lock cylinder, you may have to align the white colored ignition switch rotor (1) with the lock cylinder (2). You can rotate the ignition switch rotor (1) with your finger. 4. Turn the key to the OFF position and remove the key. 5. Install the I/P cluster trim plate. 6. Connect the negative battery cable. 7. If you installed a new lock cylinder, perform the BCM theft deterrent relearn procedure. See: Computers and Control Systems/Body Control Module/Service and Repair/Procedures/Body Control Module (BCM) Programming/RPO Configuration Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Switch Lock Cylinder - Dash Mounted > Page 4648 Ignition Switch Lock Cylinder: Service and Repair Programming/Learn Procedures Programming Replacement Lock Cylinder, BCM or PCM IMPORTANT: Reprogram the body control module (BCM) with the proper RPO configurations before you perform the learn procedures. When you replace the BCM, the module will learn Passlock Sensor Data Code immediately. However, the existing PCM must learn the new fuel continue password. When you replace a PCM, after programming, these modules will learn the incoming fuel continue password immediately upon receipt of a password message. Once a password message is received, and a password is learned, perform the learn procedure again if you want to change this password. A PCM which was previously installed in another vehicle will have learned the other vehicle's fuel continue password, and will require a learn procedure after programming in order to learn the current vehicle's password. 10 Minute Re-Learn Procedure Use this procedure after replacing any of the following components: 1. Lock Cylinders/Passlock Sensors 2. BCM 3. PCM Tech 2 Programming Procedure Use the following procedures in order to program the BCM with the Tech 2 equipment. 1. Connect the Tech 2 Diagnostic tool. 2. Select Request Information under Service Programming. 3. Disconnect the Tech 2 from the vehicle and connect it to a Techline Terminal. 4. On the Techline Terminal, select Theft Module Re-Learn under Service Programming. 5. Disconnect the Tech 2 from the Techline Terminal and connect the Tech 2 to the vehicle. 6. Turn ON the ignition, with the engine OFF. 7. Select VTD Re-Learn under Service Programming. 8. At this point you may disconnect the Tech 2, the Tech 2 is no longer required. 9. Observe the Security telltale, after approximately 10 minutes the telltale will turn OFF. The vehicle is now ready to relearn the Passlock Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. 10. Turn OFF the ignition, and wait 5 seconds. 11. Start the engine. (The vehicle has now learned keys). 12. Using a scan tool, clear any DTCs. 30 Minute Re-Learn Procedure Use this procedure after replacing lock cylinders, Passlock Module/BCM or the PCM (if necessary - see note above). 1. Turn ON the ignition, with the engine OFF. 2. Attempt to start the engine, then release the key to ON (The vehicle will not start). 3. Observe the Security telltale, after approximately 10 minutes the telltale will turn OFF. 4. Turn OFF the ignition, and wait 5 seconds. 5. Repeat steps 1-4 two more times, for a total of 3 cycles and 30 minutes. The vehicle is now ready to relearn the Passlock Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. IMPORTANT: The vehicle learns the Passlock Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. You must turn the ignition OFF before attempting to start the vehicle. 6. Start the engine. (The vehicle has now learned the Passlock Sensor Data Code and/or password.) 7. Using a scan tool, clear any DTCs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications knock Sensor 19 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations Knock Sensor: Component Locations Left Front Of Engine Knock Sensor (KS) Bank 1 Lower RR of the engine, below the exhaust manifold. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations > Page 4654 Knock Sensor: Connector Locations Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations > Page 4655 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4658 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4659 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4660 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4661 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4662 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4663 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4664 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4665 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4666 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4667 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4668 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4669 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4670 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4671 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4672 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4673 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4674 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4675 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4676 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4677 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4678 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4679 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4680 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4681 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4682 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4683 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4684 Knock Sensor (KS) 1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4685 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > General Information Knock Sensor: Description and Operation General Information The knock sensor detects abnormal vibration (spark knocking) in the engine. The sensor is located on the engine block near the cylinders. The sensor produces an AC output voltage which increases with the severity of the knock. This signal voltage is input to the PCM. The PCM then adjusts the Ignition Control (IC) timing to reduce spark knock. DTC P0325 Knock Sensor (KS) Circuit DTC P0327 Knock Sensor (KS) Circuit are designed to diagnose the PCM, the knock sensor, and related wiring, so problems encountered with the KS system should set a DTC. Refer to Knock Sensor (KS) System Description description of the knock sensor system. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > General Information > Page 4688 Knock Sensor: Description and Operation Operation The knock sensor detects abnormal vibration (spark knocking) in the engine. The knock sensor is mounted in the engine block near the cylinders and produce an AC signal under all engine operating conditions. The PCM contains integrated Knock Sensor (KS) diagnostic circuitry which uses the input signals from the knock sensors to detect engine detonation. This allows the PCM to retard Ignition Control (IC) spark timing based on the amplitude and frequency of the KS signal being received. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > General Information > Page 4689 Knock Sensor: Description and Operation Purpose Knock Sensor (KS) System Description Purpose Varying octane levels in todays gasoline may cause detonation in some engines. Detonation is caused by an uncontrolled explosion (burn) in the combustion chamber. This uncontrolled explosion could produce a flame front opposite that of the normal flame front produced by the spark plug. The rattling sound normally associated with detonation is the result of two or more opposing pressures (flame fronts) colliding within the combustion chamber. Though light detonation is sometimes considered normal, heavy detonation could result in engine damage. To control spark knock, a Knock Sensor (KS) system is used. This system is designed to retard spark timing when spark knock is detected in the engine. The KS system allows the engine to use maximum spark advance for optimal driveability and fuel economy. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Page 4690 Knock Sensor: Testing and Inspection The PCM calculates an average voltage the knock sensor signal and takes instantaneous signal voltage readings. The PCM uses the instantaneous signal voltage reading to determine the state of the knock sensor circuitry. If the knock sensor system is operating normally, the PCM should monitor instantaneous KS signal voltage readings varying outside a voltage range above and below the calculated average voltage. The following DTCs are used to diagnose the knock sensor system: ^ If the PCM malfunctions in a manner which will not allow proper diagnosis of the KS circuits, DTC P0325 will set. ^ DTC P0327 is designed to diagnose the knock sensor, and related wiring, so problems encountered with the KS system should set a DTC. However, if no DTC was set but the KS system is suspect because detonation was the customer's complaint, use the tables for P0327 to diagnose the Detonation/Spark Knock Symptom. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Page 4691 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting. 3. Disconnect the knock sensor wiring harness connector from the knock sensor. 4. Remove the knock sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Do Not apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. NOTE: Refer to Fastener Notice in Service Precautions. Knock Sensor (KS) System Deascription Purpose 1. Install the knock sensor into engine block. Tighten Tighten the knock sensor to 19 N.m (14 lb ft). 2. Connect the knock sensor wiring harness connector to the knock sensor. 3. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure - Correct Operating Range Fuel Pressure: Technical Service Bulletins Fuel Pressure - Correct Operating Range File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-018 Date: May, 1999 INFORMATION Subject: Correct Fuel Pressure Operating Range Models: 2000 Buick Century 2000 Chevrolet Impala, Lumina, Malibu, Monte Carlo, Venture 2000 Oldsmobile Alero, Silhouette 2000 Pontiac Grand Am, Grand Prix, Montana with 3.1 L or 3.4 L V6 Engine (VINs J, E - RPOs LG8, LA1) All 2000 model year 3.1 L and 3.4 L engines have a revised fuel pressure regulator and Multec II fuel injectors. The fuel system operating pressure is 358-405 kPa (52-59 psi) on these applications. Important: ^ This regulator is NOT interchangeable with past model applications. When replacement is necessary for the above listed applications, use only regulator P/N 17113622. ^ Installing regulators other than the above listed part number in these applications may result in a change in engine performance and/or driveability concerns. Refer to the Engine Controls subsection of the Service Manual for complete diagnostic and repair information on fuel system related concerns. Parts Information Part Number Description 17113622 Fuel Pressure Regulator Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 4697 Fuel Pressure: Specifications Fuel Pressure Fuel Pressure Fuel Pressure 52-59 psi Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis Fuel Pressure: Testing and Inspection Fuel System Diagnosis Diagnostic Chart (Part 1 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 4700 Diagnostic Chart (Part 2 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 4701 Diagnostic Chart (Part 3 Of 3) SYSTEM DESCRIPTION Proper fuel pressure is necessary to maintain efficient engine operation and emission levels, if fuel pressure is not within specifications vehicle driveablity may be affected or emission levels elevated. The fuel system contains the following components: ^ Fuel strainer ^ Modular fuel sender assembly ^ Fuel filter ^ Fuel feed pipes and hoses ^ Fuel pressure regulator ^ Fuel rail ^ Fuel injectors ^ Fuel return pipes and hoses TEST DESCRIPTION The numbers below refer to the step numbers on the diagnostic table. 2. Tests the fuel systems ability to achieve a specific fuel pressure range. It may be necessary to cycle the fuel pump several times to achieve the pressure range. 6. A fuel system that drops more than 5 psi in 10 minutes has a leak in one or more areas. 8. Tests the fuel systems ability to maintain a specific fuel pressure. It may be necessary to cycle the fuel pump several times to achieve the pressure range. 9. Fuel pressure that drops-off during acceleration, cruise, or hard cornering may cause a lean condition. A lean condition can cause a loss of power, surging, or misfire and may be diagnosed using a scan tool. If an extremely lean condition occurs, the oxygen sensors may drop below 500 mV and the fuel injector pulse width will increase. 13. When the engine is at idle, the manifold pressure is low, high vacuum. This low pressure, high vacuum, is applied to the fuel pressure regulator diaphragm, the result is lower fuel pressure. The fuel pressure at idle will vary slightly as the pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in Step 2 with the engine OFF. 14. This test determines if the high fuel pressure is due to a restricted fuel return pipe or fuel pressure regulator. A rich condition may cause a DTC P0132 or DTC P0172 to set. Driveability conditions associated with rich conditions can include hard starting, followed by black smoke, and a Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 4702 strong sulfur smell in the exhaust. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 4703 Fuel Pressure: Testing and Inspection Fuel System Pressure Test Diagnostic Chart (Part 1 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 4704 Diagnostic Chart (Part 2 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 4705 Diagnostic Chart (Part 3 Of 3) SYSTEM DESCRIPTION Proper fuel pressure is necessary to maintain efficient engine operation and emission levels, if fuel pressure is not within specifications vehicle driveablity may be affected or emission levels elevated. The fuel system contains the following components: ^ Fuel strainer ^ Modular fuel sender assembly ^ Fuel filter ^ Fuel feed pipes and hoses ^ Fuel pressure regulator ^ Fuel rail ^ Fuel injectors ^ Fuel return pipes and hoses TEST DESCRIPTION The numbers below refer to the step numbers on the diagnostic table. 2. Tests the fuel systems ability to achieve a specific fuel pressure range. It may be necessary to cycle the fuel pump several times to achieve the pressure range. 6. A fuel system that drops more than 5 psi in 10 minutes has a leak in one or more areas. 8. Tests the fuel systems ability to maintain a specific fuel pressure. It may be necessary to cycle the fuel pump several times to achieve the pressure range. 9. Fuel pressure that drops-off during acceleration, cruise, or hard cornering may cause a lean condition. A lean condition can cause a loss of power, surging, or misfire and may be diagnosed using a scan tool. If an extremely lean condition occurs, the oxygen sensors may drop below 500 mV and the fuel injector pulse width will increase. 13. When the engine is at idle, the manifold pressure is low, high vacuum. This low pressure, high vacuum, is applied to the fuel pressure regulator diaphragm, the result is lower fuel pressure. The fuel pressure at idle will vary slightly as the pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in Step 2 with the engine OFF. 14. This test determines if the high fuel pressure is due to a restricted fuel return pipe or fuel pressure regulator. A rich condition may cause a DTC P0132 or DTC P0172 to set. Driveability conditions associated with rich conditions can include hard starting, followed by black smoke, and a Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 4706 strong sulfur smell in the exhaust. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 4710 Idle Speed: Adjustments The Powertrain Control Module (PCM) controls engine idle speed by adjusting the position of the Idle Air Control (IAC) motor pintle. The IAC is a bi-directional motor driven by two coils. The PCM pulses current to the IAC coils in steps, counts, to extend the IAC pintle into a passage in the throttle body to decrease air flow. The PCM reverses the current pulses to retract the pintle, increasing air flow. This method allows highly accurate control of idle speed and quick response to changes in engine load. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 4720 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 4726 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 4727 Air Filter Element: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the IAT sensor electrical connector. 3. Disconnect the breather tube from the air intake duct. 4. Disconnect the MAF sensor electrical connector. 5. Loosen the air intake duct/MAF sensor hose clamps. 6. Carefully remove the air inlet hose from the throttle body and air cleaner cover. 7. Remove the 2 housing cover retaining clamps. 8, Remove the air cleaner cover (5) and carefully remove the air filter element (6). 9. Inspect the housing cover (5), seal assembly, and air ducting (2) for damage. INSTALLATION PROCEDURE 1. Carefully install the air filter element (6) into the air cleaner assembly (1). 2. Install the housing cover (5) and install the housing cover retaining screws (2). 3. Carefully install the air inlet hose to the throttle body and air cleaner cover. 4. Tighten the air inlet hose clamp. 5. Install the air intake duct/MAF sensor assembly. 6. Tighten the air intake duct/MAF sensor hose clamps. 7. Connect the breather tube to the air intake duct. 8, Connect the MAF sensor electrical connector. 9. Connect the IAT sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair RELIEF PROCEDURE Tools Required ^ J34730-1A Fuel Pressure Gauge ^ J34730-262 Fuel Pressure Gauge Fitting CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery terminal. IMPORTANT: Mount the fuel pressure gauge fitting below the belt to avoid contact with the belt. 2. Install the J 34730-262 fuel pressure gauge fitting adaptor to the fuel pressure connection. 3. Connect fuel pressure gauge J 34730-1A to the fuel gauge pressure fitting. Wrap a shop towel around the fuel pressure connection while connecting the fuel pressure gauge in order to avoid spillage. 4. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the fuel pressure gauge into an approved container. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations > Page 4735 Ignition Cable: Service Precautions NOTE: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations > Page 4736 Ignition Cable: Service and Repair REMOVAL PROCEDURE 1. Turn the ignition switch to the OFF position. 2. Note the position of the spark plug wire retaining clips. Remove the spark plug wire retaining clips from the engine. NOTE: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged. 3. Note the position of the spark plug wire(s). Remove the spark plug wires (2,4,6) from the front spark plugs by twisting the boot 1/2 turn before removing the spark plug boot(s). 4. Note the position of the spark plug wire(s). Remove the spark plug wires (1,3,5) from the rear spark plugs by twisting the boot 1/2 turn before removing the spark plug boot(s). 5. Remove the spark plug wire retaining clips from the rear of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations > Page 4737 6. Remove the spark plug wires from the ignition coils. 7. Remove the spark plug wires from the engine. 8. If replacing the spark plug wires, transfer any of the following: ^ Boot heat shields ^ Spark plug wire conduit ^ Spark plug wire retaining clips INSTALLATION PROCEDURE 1. Position the spark plug wire(s) to the engine. 2. Install the spark plug wires to the ignition coils in the proper position. 3. Install the spark plug wires (1,3,5) to the rear spark plugs. 4. Install the spark plug wire retaining clips from the rear of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations > Page 4738 5. Install the spark plug wire (2,4,6) to the front spark plugs. 6. Install the spark plug wire retaining clips to the front of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug Usage Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Spark Plug Service Precautions Spark Plug: Service Precautions Spark Plug Service Precautions NOTE: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged. NOTE: Observe the following service precautions: ^ Allow the engine to cool before removing the spark plugs. Attempting to remove spark plugs from a hot engine can cause the spark plugs to seize. This can damage the cylinder head threads. ^ Clean the spark plug recess area before removing the spark plug. Failure to do so can result in engine damage due to dirt or foreign material entering the cylinder head, or in contamination of the cylinder head threads. Contaminated threads may prevent proper seating of the new spark plug. ^ Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the vehicle. Installing spark plugs of another type can severely damage the engine. NOTE: ^ It is important to check the gap of all new and reconditioned spark plugs before installation. Pre-set gaps may have changed during handling. Use a round wire feeler gauge to be sure of an accurate check, particularly on used plugs. Installing plugs with the wrong gap can cause poor engine performance and may even damage the engine. ^ Be sure plug threads smoothly into cylinder head and is fully seated. Use a thread chaser if necessary to clean threads in cylinder head. Cross-threading or failing to fully seat spark plug can cause overheating of plug, exhaust blow-by, or thread damage. Follow the recommended torque specifications carefully. Over or under-tightening can also cause severe damage to engine or spark plug. NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Spark Plug Service Precautions > Page 4744 Spark Plug: Service Precautions Platinum Tip Spark Plug Maintenance Information Platinum Tip Spark Plug Maintenance Information for all 95-02 Models Equipped with Platinum Tip Spark Plugs The following information was originally sent to all General Motors dealers as a DCS message on October 14, 1999. Recommendation / Instructions: It has come to our attention that some GM dealers sell a customer service to remove platinum tipped spark plugs and clean the threads at regular intervals to prevent the seizure of the spark plugs in the cylinder heads at high mileage. Platinum tipped spark plugs are designed to operate under normal vehicle operating conditions for up to 100,000 miles (160,000 kms) without periodic maintenance. When no engine performance concerns are present, platinum tipped spark plugs should not be removed for periodic inspection and cleaning of threads, doing so would compromise the spark plugs ability to withstand their corrosive environment. The threaded area, although not sealed, serves as a protective environment against most harmful elements. Removing and cleaning spark plugs will introduce metallic debris and brush scrapings into the thread area which may further the corrosion process. Chromate coated spark plugs should not be wire brushed or handled in any way once they are put in service. Chromium topcoats form a protective oxide on spark plugs that is not effective if scratched. Both coated and uncoated spark plugs will have the best chance of surviving a corrosive environment if they are left in position. Attempts to maintain spark plugs by removing them and cleaning the threads can actually create the corrosive condition that the procedure was intended to prevent. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Page 4745 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ........................................................ AC Type 41-940 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Page 4746 Spark Plug: Description and Operation Worn, cracked or dirty plugs may give satisfactory operation at idling speed, but under operating conditions they frequently fail. Faulty plugs are indicated in a number of ways: poor fuel economy, loss of power and speed, hesitation, shudder, medium throttle intake manifold backfire, hard starting and general poor engine performance. Fouled plugs may be indicated by black carbon deposits. The black deposits are usually the result of slow-speed driving and short runs where sufficient engine operating temperature is seldom reached. Worn pistons, rings, faulty ignition, over-rich fuel mixture or low heat range spark plugs may result in carbon deposits. Excessive gap wear on plugs of low mileage, usually indicates the engine is operating at high speeds or loads that are consistently greater than normal or that a plug which is too hot of a heat range is being used. Electrode wear may also be the result of plug overheating, caused by combustion gases leaking past the threads, due to insufficient torque of the spark plug. Excessively lean fuel mixture will also result in excessive electrode wear. Broken insulators are usually the result of improper installation or carelessness when gapping the plug. Broken upper insulators usually result from a poor fitting wrench or an outside blow. The cracked insulator may not show up right away, but will as soon as oil or moisture penetrates the crack. The crack is usually just below the crimped part of shell and may not be visible. Broken lower insulators usually result from carelessness when gapping and generally are visible. This type of break may result from the plug operating too Hot, which may happen in periods of high-speed operation or under heavy loads. When gapping a spark plug, always make the gap adjustment by bending the ground (side) electrode. Spark plugs with broken insulators should always be replaced. Each spark plug boot covers the spark plug terminal and a portion of the plug insulator. These boots prevent flash-overwhich causes engine misfiring. Do not mistake corona discharge for flash-over or a shorted insulator. Corona is a steady blue light appearing around the insulator, just above the shell crimp. It is the visible evidence of high-tension field and has no effect on ignition performance. Usually it can be dust particles leaving a clear ring on the insulator just above the shell. This ring is sometimes mistakenly regarded as evidence that combustion gases have blown out between shell and insulator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Page 4747 Spark Plug: Testing and Inspection Normal spark plug operation will result in brown to grayish-tan deposits appearing on the portion of the spark plug that projects into the cylinder area. A small amount of red-brown, yellow, and white powdery material may also be present on the insulator tip around the center electrode. These deposits are normal combustion by-products of fuels and lubricating oils with additives. Some electrode wear will also occur. Engines which are not running properly are often referred to as misfiring. Spark plug misfiring can be indicated in a number of ways: ^ Poor fuel economy ^ Power loss ^ Loss of speed ^ Hard starting ^ Poor engine performance Flashover occurs when a damaged spark plug boot, along with dirt and moisture, permits the high voltage charge to short over the insulator to the spark plug shell or the engine. Should misfiring occur before the recommended replacement interval, locate and correct the cause. Carbon fouling of the spark plug is indicated by dry, black carbon (soot) deposits on the portion of the spark plug in the cylinder. Excessive idling or slow speeds under light engine loads can keep the spark plug temperatures so low that these deposits are not burned off. Rich fuel mixtures or poor ignition system output may also be the cause. Oil fouling of the spark plug is indicated by wet oily deposits on the portion of the spark plug in the cylinder, usually with little electrode wear. This may be caused by oil getting past worn piston rings or valve seals. This condition also may occur during break-in of new or newly overhauled engines. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Page 4748 Deposit fouling of the spark plug occurs when the normal red-brown, yellow or white deposits of combustion by-products become sufficient to cause misfiring. In some cases, these deposits may melt and form a shiny glaze on the insulator around the center electrode. If the fouling is found in only one or two cylinders, valve stem clearances or intake valve seals may be allowing excess lubricating oil to enter the cylinder, particularly if the deposits are heavier on the side of the spark plug that was facing the intake valve. Excessive gap means that the airspace between the center and side electrodes at the bottom of the spark plug is too wide for consistent spark plug firing. This may be due to improper gap adjustment or to excessive wear of the electrodes during use. Check of the gap size and compare the gap measurement to that specified for the vehicle. Excessive gap wear can be an indication of continuous operation at high speeds or with high engine loads, causing the spark plug to run too hot. Too small of a gap indicates the plug was damaged at the time of installation. Another possible cause is an excessively lean fuel mixture. Low or high spark plug installation torque or improper seating of the spark plug can result in the spark plug running too hot and cause excessive gap wear. The spark plug and cylinder head seats must be in good contact for proper heat transfer and spark plug cooling. Dirty or damaged threads in the head or on the spark plug can keep the spark plug from seating even though the proper torque is applied. Once the spark plugs are properly seated, tighten the spark plug to the proper torque. Low torque may result in poor contact of seats due to a loose spark plug. Overtightening may cause the spark plug shell to be stretched and also result in poor contact between seats. In extreme cases, exhaust blow-by and damage beyond simple gap wear may occur. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Page 4749 Cracked or broken insulators may be the result of improper installation, damage during spark plug regapping, or heat shock to the insulator material. Upper insulators can be broken when a poorly fitting tool is used during installation or removal, or when the spark plug is hit from the outside. Cracks in the upper insulator may be inside the shell and not visible. Also, the breakage may not cause problems until oil or moisture penetrates the crack later. A broken or cracked lower insulator tip (around the center electrode) can result from damage during regapping or from heat shock (spark plug suddenly operating too hot). Damage during regapping can happen if the gapping tool is pushed against the center electrode or the insulator around it, causing the insulator to crack. When regapping a spark plug, make the adjustment by only bending the side electrode. Do not contact other parts. Heat shock breakage in the lower insulator tip generally occurs during severe engine operating conditions (high-speeds or heavy-loading) and may be caused by over advanced timing or low grade fuels. Heat shock refers to a rapid increase in the tip temperature that causes the insulator material to crack. Spark plugs with less than the recommended amount of service can sometimes be cleaned and regapped, then returned to service. However, if there is any doubt about the serviceability of a spark plug, replace it. Replace spark plugs with cracked or broken insulators. In some cases, such as flashover, the ignition wire may need to be changed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Page 4750 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT Removal Procedure Tools Required J38491 Spark Plug Heat Shield Removal Tool 1. Turn OFF the ignition switch. 2. Remove the spark plug wires from the spark plugs. NOTE: ^ Allow the engine to cool before removing the spark plugs. Attempting to remove the spark plugs from a hot engine may cause the plug threads to seize, causing damage to cylinder head threads. ^ Clean the spark plug recess area before removing the spark plug. Failure to do so could result in engine damage because of dirt or foreign material entering the cylinder head, or by the contamination of the cylinder head threads. The contaminated threads may prevent the proper seating of the new plug. Use a thread chaser to clean the threads of any contamination. 3. Remove the spark plugs from the engine. Installation Procedure NOTE: ^ Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the vehicle. Installing spark plugs of another type can severely damage the engine. ^ Check the gap of all new and reconditioned spark plugs before installation. The pre-set gaps may have changed during handling. Use a round feeler gage to ensure an accurate check. Installing the spark plugs with the wrong gap can cause poor engine performance and may even damage the engine. 1. Measure the spark plug gap on the spark plugs to be installed and correct as necessary. Spark Plug Gap: 0.060 in (1.52 mm) NOTE: ^ Be sure that the spark plug threads smoothly into the cylinder head and the spark plug is fully seated. Use a thread chaser, if necessary, to clean threads in the cylinder head. Cross-threading or failing to fully seat the spark plug can cause overheating of the plug, exhaust blow-by, or thread damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service Precautions > Page 4751 2. Install the spark plugs to the engine. Torque: 15 N.m (11 ft. lb.) 3. Connect the spark plug wires to the spark plugs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The lowest reading should not be less than 70 percent of the highest reading. No cylinder reading should be less than 689 kPa (100 psi). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 4755 Compression Check: Testing and Inspection A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the head gasket. Important: Remove the Powertrain Control Module (PCM) and the ignition fuses from the I/P fuse block. 1. Disable the ignition. 2. Disable the fuel systems. 3. Remove the spark plugs from all the cylinders. 4. Remove the air duct from the throttle body. 5. Block the throttle plate in the open position. 6. Measure the engine compression, using the following procedure: 6.1. Firmly install the compression gauge to the spark plug hole. 6.2. Have an assistant crank the engine through at least 4 compression strokes in the testing cylinder. 6.3. Record the readings on the gauge at each stroke. 6.4. Disconnect the gauge. 6.5. Repeat the compression test for each cylinder. 7. Record the compression readings from all of the cylinders. - The lowest reading should not be less than 70 percent of the highest reading. - No cylinder reading should be less than 689 kPa (100 psi). 8. The following list is examples of the possible measurements: - When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each cylinder. - When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal compression, the piston rings may be the cause. - If the compression improves considerably with the addition of three squirts of oil, the piston rings may be the cause. - When the compression is low on the first stroke and does not build up in the following strokes, the valves may be the cause. - The addition of oil does not affect the compression, the valves may be the cause. - When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause. 9. Remove the block from the throttle plate. 10. Install the air duct to the throttle body. 11. Install the spark plugs. 12. Install the Powertrain Control Module (PCM) fuse. 13. Install the ignition fuse to the I/P fuse block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations LF of the engine compartment, in the air cleaner duct. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions Mass Air Flow (MAF) Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4765 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4766 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4767 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4768 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4769 Mass Air Flow (MAF) Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4770 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4771 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4772 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4773 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4774 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4775 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4776 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4777 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4778 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4779 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4780 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4781 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4782 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4783 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4784 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4785 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4786 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4787 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4788 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4789 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4790 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4791 Mass Air Flow (MAF) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4792 Mass Air Flow (MAF) Sensor: Electrical Diagrams Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4793 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Page 4794 Mass Air Flow (MAF) Sensor: Description and Operation The Mass Air Flow (MAF) sensor measures the amount of air which passes through it. The PCM uses this information to determine the operating condition of the engine, to control fuel delivery. A large quantity of air indicates acceleration, while a small quantity indicates deceleration or idle. The scan tool reads the MAF value and displays it in grams per second (gm/s). At idle, it should read between 4 gm/s to 6 gm/s on a fully warmed up engine. Values should change rather quickly on acceleration, but values should remain fairly stable at any given RPM. A failure in the MAF sensor or circuit should set DTC P0101 Mass Air Flow (MAF) Sensor Performance, DTC P0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency, or DTC P0103 Mass Air Flow (MAF) Sensor Circuit High Frequency The MAF sensor is attached to the front (air inlet side) of the throttle body and is used to measure the amount of air entering the engine. The PCM uses this information to determine the operating condition of the engine and to control fuel delivery. For further information, refer to Information Sensors/Switches Description. See: Description and Operation/Information Sensors/Switches Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Page 4795 Mass Air Flow (MAF) Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the MAF sensor (1) electrical connector. 4. Remove the air inlet duct from the MAF sensor and the throttle body. 5. Remove the MAF sensor from the air filter housing. INSTALLATION PROCEDURE 1. Install the MAF sensor to the air filter housing. 2. Install the air inlet duct to the MAF sensor and throttle body. 3. Connect the IAT sensor (1) electrical connector. 4. Connect the MAF sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Intake Air Temperature (IAT) Sensor: Locations Intake Air Temperature (IAT) Sensor is in the air induction tube. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions Intake Air Temperature (IAT) Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4801 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4802 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4803 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4804 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4805 Intake Air Temperature (IAT) Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4806 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4807 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4808 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4809 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4810 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4811 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4812 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4813 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4814 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4815 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4816 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4817 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4818 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4819 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4820 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4821 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4822 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4823 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4824 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4825 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4826 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4827 Intake Air Temperature Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4828 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Page 4829 Intake Air Temperature (IAT) Sensor: Description and Operation The Intake Air Temperature (IAT) sensor is a thermistor which changes value based on the temperature of air entering the engine. Low temperature produces a high resistance (100,000 ohms at -40°C/-40°F), while high temperature causes low resistance (70 ohms at 130°C/266°F). The PCM supplies a 5.0 volt signal to the sensor through a resistor in the PCM and measures the voltage. The voltage will be high when the incoming air is cold, and low when the air is hot. By measuring the voltage, the PCM calculates the incoming air temperature. The IAT sensor signal is used to adjust spark timing according to incoming air density. The scan tool displays temperature of the air entering the engine, which should read close to ambient air temperature when the engine is cold, and rise as the underhood temperature increases. If the engine has not been run for several hours (overnight) the IAT sensor temperature and engine coolant temperature should read close to each other. A failure in the IAT sensor circuit should set DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage or DTC P0113 Intake Air Temperature (IAT) Sensor Circuit High Voltage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Page 4830 Intake Air Temperature (IAT) Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the IAT sensor electrical connector. 3. Carefully grasp the sensor and with a twisting and pulling motion, remove the IAT sensor from air intake duct. INSTALLATION PROCEDURE 1. Install the IAT sensor (snap into place). 2. Connect the IAT sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Body Control Module: Customer Interest BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 4839 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 Body Control Module: Customer Interest Body Control Module - MIL ON/DTCs B2647/B2648 File In Section: 08 - Body and Accessories Bulletin No.: 00-08-47-002 Date: September, 2000 Subject: Service Vehicle Soon (SVS) Message, DTC B2647 and/or B2648 Set (Replace Body Control Module) Models: 2000 Chevrolet Impala, Monte Carlo Built Prior to VIN Breakpoint Y9255551 Condition Some customers may comment about a "Service Vehicle Soon" message displayed, which may or may not store diagnostic codes (DTCs) B2647 and/or B2648. Cause The headlamp auto control ambient light sensor sends a brief voltage spike to the body control module (BCM) during engine crank, which may be detected as a fault by the BCM. This may initiate the SVS message. This voltage is considered a normal condition of the ambient light sensor. Correction Replace the body control module (BCM) to correct this condition. BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: ^ The vehicle will not be protected against theft by the Passlock(TM) system. ^ The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 4844 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (* )You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 4845 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 47. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 48. Select Set Options and press Enter. 49. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 50. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 51. Select Set Option Configuration and press Enter. 52. Press the key under the highlighted Done area of the Tech 2 display. 53. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 54. Exit back to the Main Menu screen. 55. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 56. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 57. Turn the ignition switch to OFF and wait 15 seconds. 58. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 59. The Security and Battery messages will begin toggling. 60. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 61. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 4846 62. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 63. The Security and Battery messages will begin toggling. 64. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 65. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 66. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 67. The Security and Battery messages will begin toggling. 68. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 69. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 70. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Parts Information The BCM part number has not changed, but the new BCM should have a code GMAB139 or higher on the label. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Body Control Module: All Technical Service Bulletins BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 4852 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-52-001 > Feb > 04 > Keyless Entry - BCM Set-Up Programming Body Control Module: All Technical Service Bulletins Keyless Entry - BCM Set-Up Programming Bulletin No.: 04-08-52-001 Date: February 25, 2004 INFORMATION Subject: Set-up/Programming BCM for Remote Keyless Entry (RKE) Models: 2000-2004 Chevrolet Impala, Monte Carlo In the past, when replacing the BCM on the above listed vehicles, the module had to be set-up to ensure the RKE was initiated. The RKE option RPO may not have been called out individually on the SPID label when the RKE option was part of an option package. This would often lead to this option being missed during BCM set-up and leading to an inoperative RKE feature. The new BCM, P/N 10350647, currently available, will automatically toggle the RKE function on during initiation of the module. Therefore, it is no longer necessary to turn on the RKE. Just leave it on regardless if the vehicle is equipped with RKE or not. This will prevent an incorrect set-up causing this feature to become inoperative. This new BCM will also remedy a situation where some older BCMs would not remember the horn chirp setting, short or long, after going into sleep mode. Also, this new BCM will not lock the settings until after 32 key cycles compared to 15 key cycles on older BCMs. So, if a mistake is made during the initial set-up, you can re-set the module. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 Body Control Module: All Technical Service Bulletins Body Control Module - MIL ON/DTCs B2647/B2648 File In Section: 08 - Body and Accessories Bulletin No.: 00-08-47-002 Date: September, 2000 Subject: Service Vehicle Soon (SVS) Message, DTC B2647 and/or B2648 Set (Replace Body Control Module) Models: 2000 Chevrolet Impala, Monte Carlo Built Prior to VIN Breakpoint Y9255551 Condition Some customers may comment about a "Service Vehicle Soon" message displayed, which may or may not store diagnostic codes (DTCs) B2647 and/or B2648. Cause The headlamp auto control ambient light sensor sends a brief voltage spike to the body control module (BCM) during engine crank, which may be detected as a fault by the BCM. This may initiate the SVS message. This voltage is considered a normal condition of the ambient light sensor. Correction Replace the body control module (BCM) to correct this condition. BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: ^ The vehicle will not be protected against theft by the Passlock(TM) system. ^ The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 4861 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (* )You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 4862 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 47. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 48. Select Set Options and press Enter. 49. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 50. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 51. Select Set Option Configuration and press Enter. 52. Press the key under the highlighted Done area of the Tech 2 display. 53. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 54. Exit back to the Main Menu screen. 55. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 56. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 57. Turn the ignition switch to OFF and wait 15 seconds. 58. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 59. The Security and Battery messages will begin toggling. 60. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 61. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 4863 62. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 63. The Security and Battery messages will begin toggling. 64. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 65. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 66. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 67. The Security and Battery messages will begin toggling. 68. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 69. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 70. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Parts Information The BCM part number has not changed, but the new BCM should have a code GMAB139 or higher on the label. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure Body Control Module: All Technical Service Bulletins BCM - Related Service, Theft Deterrent Relearn Procedure File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-057A Date: May, 2000 INFORMATION Subject: Body Control Module (BCM) Related Service, Theft Deterrent Re-Learn Procedure Models: 2000 Chevrolet Impala, Monte Carlo This bulletin is being revised to update the service procedure and the labor time information. Please discard Corporate Bulletin Number 99-06-O4-057 (Section 6 - Engine/Propulsion System). BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: - The vehicle will not be protected against theft by the Passlock(TM) system. - The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 4868 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (*) You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 4869 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. 47. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 48. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 49. Select Set Options and press Enter. 50. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 51. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 52. Select Set Option Configuration and press Enter. 53. Press the key under the highlighted Done area of the Tech 2 display. 54. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 55. Exit back to the Main Menu screen. 56. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 57. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 58. Turn the ignition switch to OFF and wait 15 seconds. 59. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 60. The Security and Battery messages will begin toggling. 61. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 62. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 63. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 64. The Security and Battery messages will begin toggling. 65. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 66. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 67. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 4870 release the ignition switch to the RUN position (the engine will not crank). 68. The Security and Battery messages will begin toggling. 69. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 70. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 71. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N4800 Computer (Control), Body - 1.1 hrs Replace and Program Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn Body Control Module: All Technical Service Bulletins BCM - Related Service. Theft Deterrent Relearn File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-057 Date: November, 1999 INFORMATION Subject: Body Control Module (BCM) Related Service, Theft Deterrent Re-Learn Procedure Models: 2000 Chevrolet Impala, Monte Carlo BCM replacement requires that a programming function be performed. If the BCM is not properly programmed, the vehicle may not start because the Theft Lock System will be enabled. Important: If the module is not properly programmed within twenty (20) key cycles (including the VIN), the module will lock and programming will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reprogrammed. When replacing the BCM, a critical component of the procedure requires a programming of the BCM. To program the BCM, follow all of the steps in the procedure listed. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "setup new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: - The vehicle will not be protected against theft by the Passlock(TM) system. - The engine will not crank or start. Programming of the BCM requires the use of the Tech 2 scan tool. 1. Insure that the key (or ignition) switch is in the LOCK position with the ignition off. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the key to the ON position. 4. The following items all refer to the Tech 2 scan tool inputs: ^ Select Diagnostics and answer the questions when prompted by the Tech 2. ^ Select Body Control Module (BCM). ^ Select Special Functions. ^ Select New VIN and input the required data. ^ Exit back to the Special Functions menu. 5. Select BCM Programming. 6. Press the YES key when the following message is displayed: Do you want to setup a body control module? 7. The Tech 2 will then display the following message: Now setting up the New Body Control Module. 8. When the BCM has been setup successfully, the Tech 2 will display this message: Body Control Module setup is complete. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 4875 THIS MEANS THAT THE TECH 2 HAS SET THE BCM TO ACCEPT THE CORRECT INFORMATION. THIS IS NOT THE END OF THE PROGRAMMING PROCEDURE. 9. Exit back to the Special Functions menu. 10. Select Set Options. 11. Input all of the required data as prompted by the Tech 2. 12. Exit back to the Special Functions menu. 13. Select Option Configuration. 14. Input all of the required data as prompted by the Tech 2. 15. When the BCM, VIN, Point of Sale and option configuration have been entered, proceed with the Theft Deterrent Re-Learn Procedure. IF THE TECH 2 DISPLAYS "UNABLE TO PROGRAM THE BCM", THE BCM IS LOCKED. TWENTY KEY CYCLES HAVE OCCURRED SINCE THE MODULE WAS INSTALLED AND VOLTAGE WAS SUPPLIED TO THE MODULE SO THE MODULE MUST BE REPLACED AND THIS PROCEDURE MUST BE REPEATED IN ITS ENTIRETY. Important: Programming of the BCM removes any personalization settings the customer may have previously set. Inform the customer the personalization settings will have to be reset. Theft Deterrent Re-Learn Important: Perform the Theft Deterrent Re-Learn Procedure when one or more of the following conditions has occurred. - The BCM has been replaced or re-programmed (Set-up) (Configured). - The ignition key cylinder assembly has been replaced. The Theft Deterrent Re-Learn Procedure can be accomplished two different ways depending on the equipment you have available. ^ Using The Techline equipment and the Tech 2 scan tool. ^ Without Techline Equipment of any kind. This procedure takes 30 minutes and must not be shortened. USING TECHLINE EQUIPMENT AND THE TECH 2 SCAN TOOL 1. If you disconnected the scan tool from the DLC, perform the following 3 steps. If it is still connected, proceed to step 5. 2. Ensure that the key (or ignition) switch is in the LOCK position with the ignition off. 3. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 4. Turn the key to the ON position. 5. From the Main Menu screen of the Tech 2, select Service Programming. 6. Enter the requested information. 7. Select Request Info. 8. When the Tech 2 finishes gathering the information, disconnect the Tech 2 from the DLC. 9. Connect the Tech 2 to the Techline terminal. 10. Select Service Programming System (SPS). 11 Select Terminal to Tech 2 programming. 12. Select Done. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 4876 13. Follow the instructions displayed on the Techline terminal for hand-held communications set-up screen. 14. Select Theft Module Re-Learn. 15. Select program at the summary screen. The terminal will now download information into the Tech 2. 16. Disconnect the Tech 2 from the Techline terminal. 17. Re-connect the Tech 2 to the DLC. 18. At the Scan Tool Main Menu, select Service Programming. 19. Answer the Tech 2 question. 20. Select Re-Learn. 21. The PCM and BCM are now prepared for the Re-Learn procedure to begin. 22. An internal security timer will now start. The security timer is 10 minutes in duration. Important: During this 10 minute period, the scan tool must NOT be disconnected from the vehicle. Does the Tech 2 display any kind of message telling you to proceed? 23. Turn the ignition switch to the OFF position. 24. Start the engine. The engine should start and continue to run. 25. The Theft Re-Learn procedure is complete. Look for any DTCs which may have been set during this procedure. If codes were set, clear them now. Remove the Tech 2 from the vehicle. WITHOUT TECHLINE EQUIPMENT OF ANY KIND This procedure takes 30 minutes and must not be shortened. 1. Ensure that the battery is fully charged before starting this procedure. 2. Turn the ignition switch to the OFF position. 3. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 4. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 5. Turn the ignition switch to the OFF position for 5 seconds. 6. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 7. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 8. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 9. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 10. Turn the ignition switch to the OFF position for 5 seconds. 11. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will now start. 12. Using the Tech 2, look for a Clear All Trouble Codes (DTCs). Warranty Information For vehicles repaired under warranty, use: Operation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 4877 Labor Description Labor Time N4800 Computer (Control), Body - 0.7 hr Replace and Program Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 04-08-52-001 > Feb > 04 > Keyless Entry - BCM Set-Up Programming Body Control Module: All Technical Service Bulletins Keyless Entry - BCM Set-Up Programming Bulletin No.: 04-08-52-001 Date: February 25, 2004 INFORMATION Subject: Set-up/Programming BCM for Remote Keyless Entry (RKE) Models: 2000-2004 Chevrolet Impala, Monte Carlo In the past, when replacing the BCM on the above listed vehicles, the module had to be set-up to ensure the RKE was initiated. The RKE option RPO may not have been called out individually on the SPID label when the RKE option was part of an option package. This would often lead to this option being missed during BCM set-up and leading to an inoperative RKE feature. The new BCM, P/N 10350647, currently available, will automatically toggle the RKE function on during initiation of the module. Therefore, it is no longer necessary to turn on the RKE. Just leave it on regardless if the vehicle is equipped with RKE or not. This will prevent an incorrect set-up causing this feature to become inoperative. This new BCM will also remedy a situation where some older BCMs would not remember the horn chirp setting, short or long, after going into sleep mode. Also, this new BCM will not lock the settings until after 32 key cycles compared to 15 key cycles on older BCMs. So, if a mistake is made during the initial set-up, you can re-set the module. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure Body Control Module: All Technical Service Bulletins BCM - Related Service, Theft Deterrent Relearn Procedure File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-057A Date: May, 2000 INFORMATION Subject: Body Control Module (BCM) Related Service, Theft Deterrent Re-Learn Procedure Models: 2000 Chevrolet Impala, Monte Carlo This bulletin is being revised to update the service procedure and the labor time information. Please discard Corporate Bulletin Number 99-06-O4-057 (Section 6 - Engine/Propulsion System). BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: - The vehicle will not be protected against theft by the Passlock(TM) system. - The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 4887 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (*) You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 4888 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. 47. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 48. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 49. Select Set Options and press Enter. 50. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 51. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 52. Select Set Option Configuration and press Enter. 53. Press the key under the highlighted Done area of the Tech 2 display. 54. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 55. Exit back to the Main Menu screen. 56. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 57. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 58. Turn the ignition switch to OFF and wait 15 seconds. 59. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 60. The Security and Battery messages will begin toggling. 61. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 62. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 63. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 64. The Security and Battery messages will begin toggling. 65. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 66. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 67. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 4889 release the ignition switch to the RUN position (the engine will not crank). 68. The Security and Battery messages will begin toggling. 69. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 70. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 71. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N4800 Computer (Control), Body - 1.1 hrs Replace and Program Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn Body Control Module: All Technical Service Bulletins BCM - Related Service. Theft Deterrent Relearn File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-057 Date: November, 1999 INFORMATION Subject: Body Control Module (BCM) Related Service, Theft Deterrent Re-Learn Procedure Models: 2000 Chevrolet Impala, Monte Carlo BCM replacement requires that a programming function be performed. If the BCM is not properly programmed, the vehicle may not start because the Theft Lock System will be enabled. Important: If the module is not properly programmed within twenty (20) key cycles (including the VIN), the module will lock and programming will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reprogrammed. When replacing the BCM, a critical component of the procedure requires a programming of the BCM. To program the BCM, follow all of the steps in the procedure listed. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "setup new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: - The vehicle will not be protected against theft by the Passlock(TM) system. - The engine will not crank or start. Programming of the BCM requires the use of the Tech 2 scan tool. 1. Insure that the key (or ignition) switch is in the LOCK position with the ignition off. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the key to the ON position. 4. The following items all refer to the Tech 2 scan tool inputs: ^ Select Diagnostics and answer the questions when prompted by the Tech 2. ^ Select Body Control Module (BCM). ^ Select Special Functions. ^ Select New VIN and input the required data. ^ Exit back to the Special Functions menu. 5. Select BCM Programming. 6. Press the YES key when the following message is displayed: Do you want to setup a body control module? 7. The Tech 2 will then display the following message: Now setting up the New Body Control Module. 8. When the BCM has been setup successfully, the Tech 2 will display this message: Body Control Module setup is complete. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 4894 THIS MEANS THAT THE TECH 2 HAS SET THE BCM TO ACCEPT THE CORRECT INFORMATION. THIS IS NOT THE END OF THE PROGRAMMING PROCEDURE. 9. Exit back to the Special Functions menu. 10. Select Set Options. 11. Input all of the required data as prompted by the Tech 2. 12. Exit back to the Special Functions menu. 13. Select Option Configuration. 14. Input all of the required data as prompted by the Tech 2. 15. When the BCM, VIN, Point of Sale and option configuration have been entered, proceed with the Theft Deterrent Re-Learn Procedure. IF THE TECH 2 DISPLAYS "UNABLE TO PROGRAM THE BCM", THE BCM IS LOCKED. TWENTY KEY CYCLES HAVE OCCURRED SINCE THE MODULE WAS INSTALLED AND VOLTAGE WAS SUPPLIED TO THE MODULE SO THE MODULE MUST BE REPLACED AND THIS PROCEDURE MUST BE REPEATED IN ITS ENTIRETY. Important: Programming of the BCM removes any personalization settings the customer may have previously set. Inform the customer the personalization settings will have to be reset. Theft Deterrent Re-Learn Important: Perform the Theft Deterrent Re-Learn Procedure when one or more of the following conditions has occurred. - The BCM has been replaced or re-programmed (Set-up) (Configured). - The ignition key cylinder assembly has been replaced. The Theft Deterrent Re-Learn Procedure can be accomplished two different ways depending on the equipment you have available. ^ Using The Techline equipment and the Tech 2 scan tool. ^ Without Techline Equipment of any kind. This procedure takes 30 minutes and must not be shortened. USING TECHLINE EQUIPMENT AND THE TECH 2 SCAN TOOL 1. If you disconnected the scan tool from the DLC, perform the following 3 steps. If it is still connected, proceed to step 5. 2. Ensure that the key (or ignition) switch is in the LOCK position with the ignition off. 3. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 4. Turn the key to the ON position. 5. From the Main Menu screen of the Tech 2, select Service Programming. 6. Enter the requested information. 7. Select Request Info. 8. When the Tech 2 finishes gathering the information, disconnect the Tech 2 from the DLC. 9. Connect the Tech 2 to the Techline terminal. 10. Select Service Programming System (SPS). 11 Select Terminal to Tech 2 programming. 12. Select Done. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 4895 13. Follow the instructions displayed on the Techline terminal for hand-held communications set-up screen. 14. Select Theft Module Re-Learn. 15. Select program at the summary screen. The terminal will now download information into the Tech 2. 16. Disconnect the Tech 2 from the Techline terminal. 17. Re-connect the Tech 2 to the DLC. 18. At the Scan Tool Main Menu, select Service Programming. 19. Answer the Tech 2 question. 20. Select Re-Learn. 21. The PCM and BCM are now prepared for the Re-Learn procedure to begin. 22. An internal security timer will now start. The security timer is 10 minutes in duration. Important: During this 10 minute period, the scan tool must NOT be disconnected from the vehicle. Does the Tech 2 display any kind of message telling you to proceed? 23. Turn the ignition switch to the OFF position. 24. Start the engine. The engine should start and continue to run. 25. The Theft Re-Learn procedure is complete. Look for any DTCs which may have been set during this procedure. If codes were set, clear them now. Remove the Tech 2 from the vehicle. WITHOUT TECHLINE EQUIPMENT OF ANY KIND This procedure takes 30 minutes and must not be shortened. 1. Ensure that the battery is fully charged before starting this procedure. 2. Turn the ignition switch to the OFF position. 3. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 4. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 5. Turn the ignition switch to the OFF position for 5 seconds. 6. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 7. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 8. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 9. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 10. Turn the ignition switch to the OFF position for 5 seconds. 11. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will now start. 12. Using the Tech 2, look for a Clear All Trouble Codes (DTCs). Warranty Information For vehicles repaired under warranty, use: Operation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 4896 Labor Description Labor Time N4800 Computer (Control), Body - 0.7 hr Replace and Program Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Body Control Module: Component Locations Locations View LH side of the instrument panel, above parking brake. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 4899 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4902 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4903 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4904 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4905 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4906 Body Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4907 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4908 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4909 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4910 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4911 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4912 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4913 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4914 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4915 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4916 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4917 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4918 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4919 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4920 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4921 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4922 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4923 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4924 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4925 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4926 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4927 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4928 Body Control Module: Connector Views Body Control Module, C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4929 Body Control Module, C2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4930 Body Control Module, C3 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4931 Body Control Module: Electrical Diagrams Body Control Module Schematics: Door Lock Switches, LH Front Door Lock Assembly Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4932 Body Control Module Schematics: DRL Relay, Backup Relay And Ambient Light Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4933 Body Control Module Schematics: Headlamp Switch, Ignition Key Alarm Switch, Surveillance Switch And Park Brake Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4934 Body Control Module Schematics: Headlamp Dimmer Switch, Headlamp Relay, Parklamp Relay Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4935 Body Control Module Schematics: HORN Relay FOG LP Relay And Fog Lamp Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4936 Body Control Module Schematics: Interior Lights (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4937 Body Control Module Schematics: Interior Lights (Part 2 of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4938 Body Control Module Schematics: Power, Grounds and RAP Relay Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4939 Body Control Module Schematics: Brake Transaxle Shift Interlock Control, Rear Compartment Lid Release And Remote Control Door Lock Receiver Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4940 Body Control Schematics: Rear Defog Relay, Door Lock Cylinder Switches Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4941 Body Control Module Schematics: RF And Rear Door Lock Assemblys Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4942 Body Control Module Schematics: SEO Rear Compartment Lid Relay Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4943 Body Control Module Schematics: Traction Control Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description Body Control Module: Description and Operation Circuit Description General Information The Body Control Module (BCM) is capable of accomplishing multiple body control functions. Components directly connected to the BCM are controlled by the BCM's outputs. The BCM can control its outputs based on input information it obtains from sensors and switches that are directly connected to the BCM, or by borrowing information from other vehicle systems connected to the Class 2 serial data link. The BCM evaluates this information and controls certain body systems by commanding an output on or off. The BCM is also capable of commanding other vehicle systems to control functions that are not directly wired and/or controlled by the BCM. The BCM accomplishes this task by sending specific messages on the Class 2 serial data link. The vehicle system capable of performing such function will respond to the BCM message. The BCM performs these functions: ^ Audible warnings. ^ Interior lighting. ^ Automatic door locks. ^ Keyless entry (AUO option) ^ Passlock theft deterrent. ^ Content Theft (UA6 option) ^ Retained Accessory Power (RAP) RPO AUO, UA6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Audible Warnings ^ Key in ignition reminder. ^ Fasten seat belt reminder. ^ Fasten belts indicator control. ^ Parking brake reminder. ^ Turn signal reminder. ^ Low fuel reminder. ^ Headlamps ON reminder. ^ Last door closed locking confirmation. ^ Feature customization. Interior Lighting ^ Interior illumination control. ^ Delayed illumination. ^ Illuminated entry. ^ Exit illumination. ^ Theater dimming. ^ Keyless entry unlock illumination. ^ Inadvertent load (battery rundown) protection. Automatic Door Locks ^ All door unlock. ^ All door lock. ^ Last door closed locking. ^ Lockout prevention. ^ Lockout prevention override. ^ Shift into PARK unlock. ^ Shift out of PARK lock. ^ Remote driver door unlock. ^ Remote all door unlock. ^ Remote all door lock. Keyless Entry ^ Remote driver door unlock. ^ Remote all door unlock. ^ Remote all door lock. ^ Remote activation verification. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 4946 ^ Remote alarm. ^ Feature customization of remote activation verification. BCM Inputs The following components provide direct input to the BCM, plus other systems can use this input information in order to carry out certain functions: ^ A/C Request: Provides the BCM with a request signal to command the A/C compressor through the PCM via Class 2 serial data. ^ BCM Ground: Provides ground for BCM operation. ^ BCM Power: Provides voltage for BCM operation. ^ Courtesy Lights On: Provides the driver the ability to request illumination of the vehicle interior. ^ Crank Signal: Determines when the ignition switch is in the start position. ^ Dome Lamp Switch Input: Determines when the dome lamp switch (Headlamp Switch) is closed to request the dome lamp on. ^ Door Lock Switch: Door lock switch request to lock and unlock the vehicle doors. ^ Door Locks: Provides voltage for door lock actuator operation. ^ Door Open: Provides door ajar status. ^ Driver Door Open: Allows certain chime functions when the driver's door is open. ^ DRL Signal Low: This input provides the BCM with Information through an ambient light sensor for the DRL feature. ^ Exterior Lamps Off: Determines when the headlamp switch is in the OFF position. ^ Fog Lamp Switch input: This input provides the BCM with a request for fog lamps through a momentary switch connected to ground. ^ Headlamp Switch Input: Determines when the Headlamp switch is closed to request the headlamps on. ^ High Beam: Determines the status of the headlamp dimmer switch, so the BCM can send the instrument cluster a message, via Class 2, to turn on the high beam indicator. ^ Ignition 0 Signal: Determines when the ignition switch is in ACCESSORY, ON or START position. ^ Ignition 1 Signal: Determines when the ignition switch is in the ON and START positions. ^ Key In Ignition: Determines when the key is fully inserted in the ignition key cylinder. ^ Key Unlock: Determines the status of the door lock cylinder switches for content theft. ^ Lamp Request: This input requests the BCM to energize the Battery Rundown Protection relay after the car has been turned off and all the doors have been closed, so the interior lights can be turned on. ^ Park Brake Applied: Determines when the parking brake is applied. ^ Park Lamp Switch Input: Determines when the park lamp switch (Headlamp Switch) is closed to request the park lamps on. ^ Passlock Sensor Data: Reads the Passlock sensor security code. ^ Rear Compartment Ajar: Determines if the rear decklid is open or closed. ^ Rear Compartment Release: This input requests the BCM to open the rear compartment lid. ^ RFA Link: Provides an interface allowing the transfer of keyless entry information from the Remote Control Door Lock Receiver (RCDLR). ^ Serial Data: provides an interface with the PCM, EBCM, Radio, SDM, DIC and the IPC through the Class 2 serial data link. ^ Surveillance Switch Input: Determines when the surveillance switch is closed to request the surveillance mode. ^ Traction Control Request: This input provides the BCM with a request for Traction Control through a momentary switch connected to ground. BCM Outputs The BCM directly controls these outputs, plus other systems may request the BCM to control these outputs for certain functions: ^ All Door Lock: This output supplies voltage to the door lock actuators when the doors are commanded to lock. This output also supplies ground to all the door lock actuators when the doors are commanded to unlock. ^ Backup Lamp Relay Control: Provides ground to the Backup LP relay control circuit. ^ BTSI Solenoid Control: Provides ground to the Brake Transaxle Shift Interlock Control Solenoid. ^ Door Unlock: This output supplies voltage to the door lock actuators (except the driver door lock actuator) when the doors are commanded to unlock. This output also supplies ground to all the door lock actuators (except the driver door lock actuator) when the doors are commanded to lock. ^ Driver Door Unlock: This output supplies voltage to the driver door lock actuators when the doors are commanded to unlock. This output also supplies ground to the driver door lock actuator when the doors are commanded to lock. ^ DRL Relay Control: Provides ground to the DRL relay control circuit. ^ DRL 5 V Reference: Provides 5 Volts to the ambient light sensor. ^ Inadvertent Load Relay Control Output: Supplies ground to the battery rundown protection relay providing an inadvertent load (battery rundown) protection. ^ Fog Lamp Enable Control: Sends a ground signal to the fog lamp switch when the ignition switch on; this action enables the fog lamp switch. The fog lamps turn on when the fog lamp switch is enabled by the BCM. ^ Headlamp Relay Control: Provides ground to the Headlamp relay control circuit. ^ Horn: Sends a ground signal to the horn relay, sounding the horn for the keyless entry alarm function or the content theft system. ^ Inadvertent Relay Control: Provides ground to the Battery Rundown Protection relay control circuit. ^ Interior Dimming: Controls the voltage to the interior lights dimming system. ^ Load Management Control: Provides voltage to the Rear Defogger relay control circuit and the Heated Seats. ^ Park Lamp Relay Control: Provides ground to the Park Lamp relay control circuit. ^ Passlock Sensor Power: Provides B+ for Passlock sensor operation. ^ Passlock Sensor Ground: Provides ground to the Passlock sensor. ^ RAP Relay Control: Provides voltage to the RAP relay control feed circuit. ^ Rear Compartment Lid Release Output: Provides ground to Rear Compartment Lid Release Actuator. ^ RFA Link: Provides an interface allowing the transfer of keyless entry information to the Remote Control Door Lock Receiver (RCDLR). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 4947 ^ Serial Data: provides an interface with the PCM, EBCM, Radio, SDM, DIC and the IPC through the Class 2 serial data link. ^ Theater Dimming 1 Control: Supplies ground to activate the Footwell lamps. ^ Theater Dimming 2 Control: Supplies ground to activate the inside rear view mirror lamps, non SEO dome lamp, and the roof rail courtesy/reading lamps. BCM Wake-Up/Sleep State The BCM performs its functions in the wake-up state. The BCM enters the sleep state when active control or monitoring of system malfunctions has stopped, or when the BCM is idling. The BCM must detect certain wake-up inputs before entering the wake-up state. The BCM monitors its inputs during the sleep state, allowing the BCM to switch between the two states, awake or asleep. The BCM enters the wake-up state when receiving activity on any of these inputs: ^ I/P dimmer switch. ^ Door lock (ajar) switch. ^ Door lock switch. ^ A keyless entry system signal. ^ Inadvertent power (battery rundown) protection transition. ^ The ignition is turned to the LOCK, ACCESSORY or the ON position. The sleep state is when the BCM has stopped active control and monitoring of system functions and has become idle again. For the BCM to enter the wake-up state, the BCM must detect a wake-up condition, mentioned previously. These conditions are called wake-up inputs that cause the BCM to change from a sleep to a wake-up state and begin active control and monitoring. The BCM has the ability to monitor for these wake-up inputs in the sleep state. The BCM enters the sleep state when all of these conditions exist: ^ No activity on the Class 2 serial data link. ^ The ignition switch is in the OFF position. ^ The BCM is not commanding any outputs. ^ No delay timers are actively counting (during theft deterrent re-learn). ^ No wake-up inputs are present. Content Theft (UA6 Option) The Body Control Module features a content theft deterrent system which is designed to defer vehicle vandalism and theft. The content theft deterrent system performs these functions: ^ Flashes the headlamps ^ Sounds the horns ^ Disables fuel delivery to the engine The BCM monitors the following: ^ Status of the doors ^ Lock cylinders ^ Rear compartment lid ^ Power door locks ^ The keyless entry system The BCM operates the headlamps, horns and the theft deterrent indicator, thats in the radio, according to the mode of operation the system is in. The BCM also communicates a fuel enable signal to the Powertrain Control Module (PCM) when the system is armed. Refer to Content Theft Deterrent (CTD) Operation in Theft Deterrent for more information. RPO UA6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Miscellaneous Functions ^ BRAKE indicator lamp control: The BCM controls the state of the BRAKE indicator lamp based on the status of the parking brake switch by sending a message to the instrument cluster via the Class 2 serial data link. ^ Fog lamp enable control. The BCM controls fog lamp operation, based on the status of the ignition switch. ^ Day/night mode sensing: The BCM determines the ambient light operating mode. The BCM then communicates the information to the Instrument Cluster and Powertrain Control Module (PCM) via the Class 2 serial data link. Passlock Theft Deterrent The Passlock is a vehicle theft deterrent system. The Passlock theft deterrent system contains a Passlock sensor. The Passlock sensor is part of the ignition lock cylinder assembly. The Body Control Module (BCM) provides power and ground to the Passlock sensor. The Passlock sensor interfaces with the BCM through the Passlock detection circuit. When turning the ignition switch to the start position with the proper key, the Passlock sensor generates an analog voltage signal. This signal is sent through the Passlock detecting circuit. This analog voltage signal is of a specific value to the vehicle, and varies from vehicle to vehicle. When attempting to start the engine, the BCM compares a preset stored analog voltage value with the signal coming from the sensor. Because both values Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 4948 match, the BCM sends a fuel enable password via the Class 2 serial data link to the Powertrain Control Module (PCM). As a result, the PCM enables the crank relay, and allows fuel delivery to the engine. When attempting to start the engine by means other than using the proper key in the ignition switch, the Passlock sensor sends an analog voltage signal of a different value. The BCM compares the preset stored analog voltage value with the signal coming from the sensor. Because both values do not match, the BCM sends a fuel disable password via the Class 2 serial data link to the Powertrain Control Module (PCM). As a result, the PCM disables the crank relay, and does not allow fuel delivery to the engine. Power Requirements The BCM has three main voltage feeds and two grounds. The voltage feed circuits are used to provide power for the BCM's logic, courtesy lights, internal driver operation and the door locks. Retained Accessory Power (RAP) The Accessory Power (RAP) feature allows the operation of the following functions for 10 minutes (or until a vehicle door opens) after the ignition switch has been turned from the ON or ACCESSORY position to the LOCK position: ^ The radio ^ The power windows ^ The power sunroof (if equipped) Refer to Keyless Entry System Operation in Retained Accessory Power (RAP) for more information. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 4949 Body Control Module: Description and Operation System Operation General Information The Body Control Module (BCM) is capable of accomplishing multiple body control functions. Components directly connected to the BCM are controlled by the BCM's outputs. The BCM can control its outputs based on input information it obtains from sensors and switches that are directly connected to the BCM, or by borrowing information from other vehicle systems connected to the Class 2 serial data link. The BCM evaluates this information and controls certain body systems by commanding an output on or off. The BCM is also capable of commanding other vehicle systems to control functions that are not directly wired and/or controlled by the BCM. The BCM accomplishes this task by sending specific messages on the Class 2 serial data link. The vehicle system capable of performing such function will respond to the BCM message. The BCM performs these functions: ^ Audible warnings. ^ Interior lighting. ^ Automatic door locks. ^ Keyless entry (AUO option) ^ Passlock theft deterrent. ^ Content Theft (UA6 option) ^ Retained Accessory Power (RAP) RPO UA6, AUO: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Audible Warnings ^ Key in ignition reminder. ^ Fasten seat belt reminder. ^ Fasten belts indicator control. ^ Parking brake reminder. ^ Turn signal reminder. ^ Low fuel reminder. ^ Headlamps ON reminder. ^ Last door closed locking confirmation. ^ Feature customization. Interior Lighting ^ Interior illumination control. ^ Delayed illumination. ^ Illuminated entry. ^ Exit illumination. ^ Theater dimming. ^ Keyless entry unlock illumination. ^ Inadvertent load (battery rundown) protection. Automatic Door Locks ^ All door unlock. ^ All door lock. ^ Last door closed locking. ^ Lockout prevention. ^ Lockout prevention override. ^ Shift into PARK unlock. ^ Shift out of PARK lock. ^ Remote driver door unlock. ^ Remote all door unlock. ^ Remote all door lock. Keyless Entry ^ Remote driver door unlock. ^ Remote all door unlock. ^ Remote all door lock. ^ Remote activation verification. ^ Remote alarm. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 4950 ^ Feature customization of remote activation verification. BCM Wake-Up/Sleep State The BCM performs its functions in the wake-up state. The BCM enters the sleep state when active control or monitoring of system malfunctions has stopped, or when the BCM is idling. The BCM must detect certain wake-up inputs before entering the wake-up state. The BCM monitors its inputs during the sleep state, allowing the BCM to switch between the two states, awake or asleep. The BCM enters the wake-up state when receiving activity on any of these inputs: ^ I/P dimmer switch. ^ Door lock (ajar) switch. ^ Door lock switch. ^ A keyless entry system signal. ^ Inadvertent power (battery rundown) protection transition. ^ The ignition is turned to the LOCK, ACCESSORY or the ON position. The sleep state is when the BCM has stopped active control and monitoring of system functions and has become idle again. For the BCM to enter the wake-up state, the BCM must detect a wake-up condition, mentioned previously. These conditions are called wake-up inputs that cause the BCM to change from a sleep to a wake-up state and begin active control and monitoring. The BCM has the ability to monitor for these wake-up inputs in the sleep state. The BCM enters the sleep state when all of these conditions exist: ^ No activity on the Class 2 serial data link. ^ The ignition switch is in the OFF position. ^ The BCM is not commanding any outputs. ^ No delay timers are actively counting (during theft deterrent re-learn). ^ No wake-up inputs are present. Content Theft (UA6 Option) The Body Control Module features a content theft deterrent system which is designed to defer vehicle vandalism and theft. The content theft deterrent system performs these functions: ^ Flashes the headlamps ^ Sounds the horns ^ Disables fuel delivery to the engine The BCM monitors the following: ^ Status of the doors ^ Lock cylinders ^ Rear compartment lid ^ Power door locks ^ The keyless entry system The BCM operates the headlamps, horns and the theft deterrent indicator, thats in the radio, according to the mode of operation the system is in. The BCM also communicates a fuel enable signal to the Powertrain Control Module (PCM) when the system is armed. Refer to Content Theft Deterrent (CTD) Operation in Theft Deterrent for more information. RPO UA6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Power Requirements The BCM has three main voltage feeds and two grounds. The voltage feed circuits are used to provide power for the BCM's logic, courtesy lights, internal driver operation and the door locks. BCM Inputs The following components provide direct input to the BCM, plus other systems can use this input information in order to carry out certain functions: ^ A/C Request: Provides the BCM with a request signal to command the A/C compressor through the PCM via Class 2 serial data. ^ BCM Ground: Provides ground for BCM operation. ^ BCM Power: Provides voltage for BCM operation. ^ Courtesy Lights On: Provides the driver the ability to request illumination of the vehicle interior. ^ Crank Signal: Determines when the ignition switch is in the start position. ^ Dome Lamp Switch Input: Determines when the dome lamp switch (Headlamp Switch) is closed to request the dome lamp on. ^ Door Lock Switch: Door lock switch request to lock and unlock the vehicle doors. ^ Door Locks: Provides voltage for door lock actuator operation. ^ Door Open: Provides door ajar status. ^ Driver Door Open: Allows certain chime functions when the driver's door is open. ^ DRL Signal Low: This input provides the BCM with Information through an ambient light sensor for the DRL feature. ^ Exterior Lamps Off: Determines when the headlamp switch is in the OFF position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 4951 ^ Fog Lamp Switch input: This input provides the BCM with a request for fog lamps through a momentary switch connected to ground. ^ Headlamp Switch Input: Determines when the Headlamp switch is closed to request the headlamps on. ^ High Beam: Determines the status of the headlamp dimmer switch, so the BCM can send the instrument cluster a message, via Class 2, to turn on the high beam indicator. ^ Ignition 0 Signal: Determines when the ignition switch is in ACCESSORY, ON or START position. ^ Ignition 1 Signal: Determines when the ignition switch is in the ON and START positions. ^ Key In Ignition: Determines when the key is fully inserted in the ignition key cylinder. ^ Key Unlock: Determines the status of the door lock cylinder switches for content theft. ^ Lamp Request: This input requests the BCM to energize the Battery Rundown Protection relay after the car has been turned off and all the doors have been closed, so the interior lights can be turned on. ^ Park Brake Applied: Determines when the parking brake is applied. ^ Park Lamp Switch Input: Determines when the park lamp switch (Headlamp Switch) is closed to request the park lamps on. ^ Passlock Sensor Data: Reads the Passlock sensor security code. ^ Rear Compartment Ajar: Determines if the rear decklid is open or closed. ^ Rear Compartment Release: This input requests the BCM to open the rear compartment lid. ^ RFA Link: Provides an interface allowing the transfer of keyless entry information from the Remote Control Door Lock Receiver (RCDLR). ^ Serial Data: provides an interface with the PCM, EBCM, Radio, SDM, DIC and the IPC through the Class 2 serial data link. ^ Surveillance Switch Input: Determines when the surveillance switch is closed to request the surveillance mode. ^ Traction Control Request: This input provides the BCM with a request for Traction Control through a momentary switch connected to ground. BCM Outputs The BCM directly controls these outputs, plus other systems may request the BCM to control these outputs for certain functions: ^ All Door Lock: This output supplies voltage to the door lock actuators when the doors are commanded to lock. This output also supplies ground to all the door lock actuators when the doors are commanded to unlock. ^ Backup Lamp Relay Control: Provides ground to the Backup LP relay control circuit. ^ BTSI Solenoid Control: Provides ground to the Brake Transaxle Shift Interlock Control Solenoid. ^ Door Unlock: This output supplies voltage to the door lock actuators (except the driver door lock actuator) when the doors are commanded to unlock. This output also supplies ground to all the door lock actuators (except the driver door lock actuator) when the doors are commanded to lock. ^ Driver Door Unlock: This output supplies voltage to the driver door lock actuators when the doors are commanded to unlock. This output also supplies ground to the driver door lock actuator when the doors are commanded to lock. ^ DRL Relay Control: Provides ground to the DRL relay control circuit. ^ DRL 5 V Reference: Provides 5 Volts to the ambient light sensor. ^ Inadvertent Load Relay Control Output: Supplies ground to the battery rundown protection relay providing an inadvertent load (battery rundown) protection. ^ Fog Lamp Enable Control: Sends a ground signal to the fog lamp switch when the ignition switch on; this action enables the fog lamp switch. The fog lamps turn on when the fog lamp switch is enabled by the BCM. ^ Headlamp Relay Control: Provides ground to the Headlamp relay control circuit. ^ Horn: Sends a ground signal to the horn relay, sounding the horn for the keyless entry alarm function or the content theft system. ^ Inadvertent Relay Control: Provides ground to the Battery Rundown Protection relay control circuit. ^ Interior Dimming: Controls the voltage to the interior lights dimming system. ^ Load Management Control: Provides voltage to the Rear Defogger relay control circuit and the Heated Seats. ^ Park Lamp Relay Control: Provides ground to the Park Lamp relay control circuit. ^ Passlock Sensor Power: Provides B+ for Passlock sensor operation. ^ Passlock Sensor Ground: Provides ground to the Passlock sensor. ^ RAP Relay Control: Provides voltage to the RAP relay control feed circuit. ^ Rear Compartment Lid Release Output: Provides ground to Rear Compartment Lid Release Actuator. ^ RFA Link: Provides an interface allowing the transfer of keyless entry information to the Remote Control Door Lock Receiver (RCDLR). ^ Serial Data: provides an interface with the PCM, EBCM, Radio, SDM, DIC and the IPC through the Class 2 serial data link. ^ Theater Dimming 1 Control: Supplies ground to activate the Footwell lamps. ^ Theater Dimming 2 Control: Supplies ground to activate the inside rear view mirror lamps, non SEO dome lamp, and the roof rail courtesy/reading lamps. Miscellaneous Functions ^ BRAKE indicator lamp control: The BCM controls the state of the BRAKE indicator lamp based on the status of the parking brake switch by sending a message to the instrument cluster via the Class 2 serial data link. ^ Fog lamp enable control. The BCM controls fog lamp operation, based on the status of the ignition switch. ^ Day/night mode sensing: The BCM determines the ambient light operating mode. The BCM then communicates the information to the Instrument Cluster and Powertrain Control Module (PCM) via the Class 2 serial data link. Passlock Theft Deterrent The Passlock is a vehicle theft deterrent system. The Passlock theft deterrent system contains a Passlock sensor. The Passlock sensor is part of the ignition lock cylinder assembly. The Body Control Module (BCM) provides power and ground to the Passlock sensor. The Passlock sensor interfaces with the BCM through the Passlock detection circuit. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 4952 When turning the ignition switch to the start position with the proper key, the Passlock sensor generates an analog voltage signal. This signal is sent through the Passlock detecting circuit. This analog voltage signal is of a specific value to the vehicle, and varies from vehicle to vehicle. When attempting to start the engine, the BCM compares a preset stored analog voltage value with the signal coming from the sensor. Because both values match, the BCM sends a fuel enable password via the Class 2 serial data link to the Powertrain Control Module (PCM). As a result, the PCM enables the crank relay, and allows fuel delivery to the engine. When attempting to start the engine by means other than using the proper key in the ignition switch, the Passlock sensor sends an analog voltage signal of a different value. The BCM compares the preset stored analog voltage value with the signal coming from the sensor. Because both values do not match, the BCM sends a fuel disable password via the Class 2 serial data link to the Powertrain Control Module (PCM). As a result, the PCM disables the crank relay, and does not allow fuel delivery to the engine. Retained Accessory Power (RAP) The Retained Accessory Power (RAP) feature allows the operation of the following functions for 10 minutes (or until a vehicle door opens) after the ignition switch has been turned from the ON or ACCESSORY position to the LOCK position: ^ The radio ^ The power windows ^ The power sunroof (if equipped) Refer to Keyless Entry System Operation in Retained Accessory Power (RAP) for more information. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Body Control Module: Initial Inspection and Diagnostic Overview A Diagnostic Starting Point - Body Control System Begin the diagnosis of the body control system by performing the Diagnostic System Check for the system in which the customer concern is apparent. The Diagnostic System Check will direct you to the correct procedure for diagnosing the system and where the procedure is located. A Diagnostic System Check - Body Control System A Diagnostic System Check-Body Control System TEST DESCRIPTION The number(s) below refer to the step number(s) on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 4. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Code Setting Criteria (Fault) For Device Power Moding Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4955 Body Control Module: Reading and Clearing Diagnostic Trouble Codes With Diagnostic Scan Tool PROCEDURE A Tech II or equivalent Scan tool must be used to retrieve Diagnostic Trouble Codes (DTCs) from the PCM or BCM memory. DTCs can no longer be retrieved at the data link connector. This also eliminates the PCM function of flashing Code 12. Follow the instructions supplied by the Scan tool manufacturer in order to access and read either current and/or history DTCs. Without Diagnostic Scan Tool A Tech II or equivalent scan tool must be used to retrieve Diagnostic Trouble Codes (DTCs) from the PCM memory. DTCs can no longer be retrieved at the data link connector. This also eliminates the PCM function of flashing Code 12. Follow the instructions supplied by the scan tool manufacturer in order to access and read either current and/or history DTCs. With Diagnostic Scan Tool PROCEDURE Use a Tech II or equivalent Scan tool to clear Diagnostic Trouble Codes (DTCs) from the PCM memory. When clearing DTCs, follow the instructions supplied by the Scan tool manufacturer. NOTES: ^ Do not clear the DTCs unless directed to do so by the service information provided for each diagnostic procedure. All of the diagnostic data that was saved along with the DTC (freeze frame data and/or malfunction history records) which may be helpful for some diagnostic procedures will be erased from the memory when the DTCs are cleared. ^ Interrupting PCM battery voltage to clear DTCs is NOT recommended. Without Diagnostic Scan Tool PROCEDURE Use a Tech II or equivalent Scan tool to clear Diagnostic Trouble Codes (DTCs) from the PCM memory. When clearing DTCs, follow the instructions supplied by the Scan tool manufacturer. NOTES: ^ Do not clear the DTCs unless directed to do so by the service information provided for each diagnostic procedure. All of the diagnostic data that was saved along with the DTC (freeze frame data and/or malfunction history records) which may be helpful for some diagnostic procedures will be erased from the memory when the DTCs are cleared. ^ Interrupting PCM battery voltage to clear DTCs is NOT recommended. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4956 Body Control Module: Scan Tool Testing and Procedures Scan Tool Data Definitions Doors Battery Fd: The scan tool displays Inactive/Active. The input of the Doors Battery Fd is displayed as Active. Electronics Battery Fd: The scan tool displays Inactive/Active. The input of the Electronics Battery Fd is displayed as Active. Electronics System Gnd: The scan tool displays Inactive/Active. The input of the Electronics System Gnd is displayed as Active. Ignition 0: The scan tool displays On/Off. The input of the Ignition 0 varies on the scan tool display. Ignition 1: The scan tool displays On/Off. The input of the Ignition 1 varies on the scan tool display. Ignition 3: The scan tool displays On/Off. The input of the Ignition 3 varies on the scan tool display. Inadvert Power Relay: The scan tool displays On/Off. The input of the Inadvert Power Output varies on the scan tool display Loads Battery Fd: The scan tool displays Inactive/Active. The input of the Loads Battery Fd is displayed as Active. Loads System Gnd: The scan tool displays Inactive/Active. The input of the Loads System Gnd is displayed as Active. Theater Dim 1 Ground: The scan tool displays Inactive/Active. The input of the Theater Dim 1 Ground is displayed as Inactive. Theater Dim 2 Ground: The scan tool displays Inactive/Active. The input of the Theater Dim 2 Ground is displayed as Inactive. Scan Tool Data List Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures Body Control Module (BCM) Programming/RPO Configuration INTRODUCTION During body control module (BCM) related service, the procedures below are designated to set-up the BCM correctly. Before you start, read these procedures carefully and completely. SETUP NEW BODY CONTROL MODULE (BCM) IMPORTANT: ^ The BCM will not function properly if the Setup New BCM procedure is not performed. ^ Make sure the battery is fully charged before performing the setup procedure. ^ Make sure all disconnected devices and connectors have been reconnected ^ Perform the Theft Deterrent Re-learn procedure after successfully finishing the Setup New BCM procedure. Refer to Programming Theft Deterrent System Components in Theft Deterrent. If the Theft Deterrent Re-learn procedure is not performed after a BCM replacement, the following conditions may occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank nor start. 1. Connect a scan tool to the data link connector (DLC). 2. Turn the ignition switch ON. 3. Select Diagnostics and input all of the required data when prompted by the scan tool. 4. Select BODY CONTROL MODULE. 5. Select SPECIAL FUNCTIONS. 6. Select Setup New BCM. 7. Note, Input all of the required data when prompted by the scan tool. 8. Select Setup SDM Part Number in BCM, and follow the onscreen directions. 9. Select New VIN, and follow the onscreen directions. 10. Select Option Configuration, and follow the onscreen directions. 11. Select Point of Sale, and follow the onscreen directions. 12. Exit back to the SPECIAL FUNCTIONS menu. 13. When the BCM, VIN, Point of Sale and Option Configuration have been entered, proceed with Theft Deterrent Re-learn procedure. 14. If the scan tool displays UNABLE TO PROGRAM BCM, BCM IS SECURED, then the BCM must be replaced and this procedure must be repeated on a new BCM.. NOTE: After the above procedure has been completed, personalization of the BCM defaults to a default setting. Inform the customer that the personalization settings must be set again. IMPORTANT: After programing, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve History DTCs from all modules. 5. Clear all history DTCs General Information During Body Control Module (BCM) related service, the procedures below are designated to set-up the BCM correctly. Before you start, read these procedures carefully and completely. Theft Deterrent Re-Learn Using T-50 or T-60 1. Enter the T-50 or T-60 Service Programming System (SPS). 2. Select TERMINAL TO VEHICLE PROGRAMMING. 3. Select DONE. 4. Follow the instructions on the VEHICLE SETUP screen. 5. Select THEFT MODULE RE-LEARN. 6. Follow the instructions on the remaining screens. 7. The PCM and BCM will be prepared for re-learn. 8. A security timer will be on for approximately 10 minutes. During the 10 minute wait period, the T-50 or T-60 terminal must remain connected to the vehicle. 9. When the PCM and BCM are prepared to re-learn, turn the ignition switch off. 10. Turn the ignition switch to start. The vehicle should now start. Theft Deterrent Re-Learn W/O Scan Tool Or Techline Equipment This procedure takes approximately 30 minutes. Make sure the battery is fully charged before proceeding. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 4959 1. Turn the ignition switch off. 2. Turn the ignition switch all the way from the off to the start position, then leave it in the on position. NOTE: The engine will not crank. 3. The SECURITY will come on and stay on for at least 10 minutes. 4. Turn the ignition switch off for five seconds. 5. Repeat steps 2, 3, and 4 again for a second time. 6. Repeat steps 2, 3, and 4 again for a third time. 7. Turn the ignition switch off. 8. Turn the ignition switch all the way to the start position. The engine should now start. 9. Check for BCM Diagnostic Trouble Codes (DTCs). Theft Deterrent Re-Learn With Techline Equip & Tech 2 Scan Tool 1. Connect the Scan Tool to the Data Link Connector (DLC) on the vehicle. 2. At the Scan Tool main menu, select SERVICE PROGRAMMING. 3. Enter the requested information. 4. Select REQUEST INFO. 5. Disconnect the Scan Tool from the vehicle. 6. Connect the Scan Tool to the Techline terminal. 7. Select SERVICE PROGRAMMING SYSTEM (SPS). 8. Select TERMINAL TO TECH 2 PROGRAMMING. 9. Select DONE. 10. Follow instructions on the Techline terminal to Handheld Communications Setup screen. 11. Select THEFT MODULE RE-LEARN. 12. Select PROGRAM at the summary screen. The terminal will download information to the Scan Tool. 13. Disconnect the Scan Tool from the Techline terminal. 14. Connect the Scan Tool to the DLC on the vehicle. 15. At the Scan Tool main menu, select SERVICE PROGRAMMING. 16. Answer the question prompted by the Scan Tool. 17. Select RE-LEARN. 18. The Powertrain Control Module (PCM) and the BCM will be prepared for re-learn. 19. A security timer will be on for approximately 10 minutes. During the 10 minute wait period, Scan Tool must remain connected to the vehicle. 20. Turn the ignition switch off when the re-learn procedure is complete. 21. Turn the ignition switch to the start position. 22. The engine should start when the ignition switch is turned to the start position. 23. Disconnect the Scan Tool from the DLC. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 4960 Body Control Module: Removal and Replacement Body Control Module Replacement REMOVAL PROCEDURE IMPORTANT: You must perform the new body control module (BCM) setup when replacing the BCM. Refer to BCM Programming/RPO Configuration. 1. Disconnect the battery ground (negative) cable. 2. Remove the left instrument panel insulator. 3. Disconnect the BCM electrical connectors (2, 3, 4). 4. Remove the BCM (1). INSTALLATION PROCEDURE 1. Install the body control module (BCM) (1). 2. Connect the BCM electrical connectors (2, 3, 4). 3. Install the left instrument panel insulator 4. Connect the battery ground (negative) cable. 5. Perform the new BCM setup. Refer to BCM Programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 89 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations RH side of the engine, below the intake plenum. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 4966 Camshaft Position Sensor: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 4967 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4970 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4971 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4972 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4973 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4974 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4975 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4976 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4977 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4978 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4979 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4980 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4981 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4982 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4983 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4984 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4985 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4986 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4987 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4988 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4989 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4990 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4991 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4992 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4993 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4994 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4995 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4996 Camshaft Position Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position (CMP) Sensor and Cam Signal Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor and Cam Signal The camshaft position sensor sends a cam signal to the PCM which uses it as a sync pulse to trigger the injectors in proper sequence. The PCM uses the CAM signal to indicate the position of the #1 piston during its intake stroke. This allows the PCM to calculate true Sequential Fuel Injection (SFI) mode of operation. If the PCM detects an incorrect CAM signal while the engine is running, DTC P0341 Camshaft Position (CMP) Sensor Performance will set. If the CAM signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection mode based on the last fuel injection pulse, and the engine will continue to run. The engine can be restarted and will run in the calculated sequential mode as long as the fault is present with a 1 in 6 chance of injector sequence being correct. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position (CMP) Sensor and Cam Signal > Page 4999 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The camshaft position sensor is located on the timing cover behind the water pump near the camshaft sprocket. As the camshaft sprocket turns, a magnet in it activates the Hall-effect switch in the camshaft position sensor. When the Hall-effect switch is activated, it grounds the signal line to the PCM, pulling the camshaft position sensor signal circuit's applied voltage low. This is interpreted as a CAM signal. The CAM signal is created as piston #1 is on the intake stroke. If the correct CAM signal is not received by the PCM, DTC P0341 will be set. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 5000 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the serpentine drive belt. 3. Loosen the power steering pump to gain access to the CMP. 4. Disconnect the sensor electrical connector. 5. Remove the attaching bolt. 6. Remove the sensor. 7. Inspect the sensor for wear, cracks or leakage if the sensor is not being replaced. INSTALLATION PROCEDURE 1. Lubricate the O-ring with clean engine oil and replace if damaged. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the camshaft position sensor. Tighten Tighten the retaining bolt to 10 N.m (88 lb in). 3. Connect the sensor electrical connector. 4. Install the power steering pump. 5. Reinstall the serpentine drive belt. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor 23 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 5004 Coolant Temperature Sensor/Switch (For Computer): Locations LH side, top of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5007 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5008 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5009 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5010 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5011 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5012 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5013 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5014 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5015 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5016 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5017 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5018 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5019 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5020 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5021 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5022 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5023 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5024 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5025 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5026 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5027 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5028 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5029 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5030 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5031 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5032 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5033 Engine Coolant Temperature (ECT) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5034 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 5035 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The engine coolant temperature sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance (100,000 ohms at -40°C/-40°F) while high temperature causes low resistance (70 ohms at 130° C/266° F). The PCM supplies a 5.0 volt signal to the engine coolant temperature sensor through a resistor in the PCM and measures the voltage. The voltage will be high when the engine is cold, and low when the engine is hot. By measuring the voltage, the PCM calculates the engine coolant temperature. Engine coolant temperature affects most systems the PCM controls. The scan tool displays engine coolant temperature in degrees. After engine startup, the temperature should rise steadily to about 90°C (194°F) then stabilize when thermostat opens. If the engine has not been run for several hours (overnight), the engine coolant temperature and intake air temperature displays should be close to each other. A hard fault in the engine coolant sensor circuit should set DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage, or DTC P0118 Engine Coolant Temperature (ECT) Sensor Circuit High Voltage, an intermittent fault should set a DTC P1114 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent Low Voltage, or DTC P1115 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent High Voltage. The DTC Diagnostic Aids also contains a chart to test for sensor resistance values relative to temperature. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 5036 The ECT sensor (3) also contains another circuit which is used to operate the engine coolant temperature gauge located in the instrument panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 5037 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Relieve coolant pressure. 3. Disconnect the ECT sensor electrical connector. 4. Using a deep well socket and extension, remove the sensor. INSTALLATION PROCEDURE 1. Coat the engine coolant temperature sensor threads with sealer P/N 9985253 or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the sensor in the engine. Tighten Tighten the sensor to 23 N.m (17 lb ft). 3. Connect the ECT sensor electrical connector. 4. Start the engine. 5. Inspect for leaks. 6. Inspect the coolant level. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt Front Cover 89 in.lb Crankshaft Position Sensor Stud Side of Engine Block 98 in.lb Crankshaft Position Sensor Wiring Bracket Bolt 37 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 5043 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 5044 Locations View Crankshaft Position (24X) Sensor RH side of the engine, at the end of the crankshaft, behind the harmonic balancer. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 5045 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5048 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5049 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5050 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5051 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5052 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5053 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5054 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5055 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5056 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5057 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5058 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5059 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5060 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5061 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5062 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5063 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5064 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5065 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5066 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5067 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5068 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5069 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5070 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5071 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5072 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5073 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5074 Crankshaft Position Sensor (24X) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 7X Crankshaft Position (CKP) Sensor Crankshaft Position Sensor: Description and Operation 7X Crankshaft Position (CKP) Sensor The 7X crankshaft position sensor provides a signal used by the ignition control module. The ignition control module also uses the 7X crankshaft position sensor to generate 3X reference pulses which the PCM uses to calculate RPM and crankshaft position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 7X Crankshaft Position (CKP) Sensor > Page 5077 Crankshaft Position Sensor: Description and Operation 24X Crankshaft Position (CKP) Sensor 24X Crankshaft Position (CKP) Sensor The 24X crankshaft position (CKP) sensor (1) is used to improve idle spark control at engine speeds up to approximately 1600 RPM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure The Crankshaft Position System Variation compensating values are stored in the PCM non-volatile memory after a learn procedure has been performed. If the actual Crankshaft Position System Variation is not within the Crankshaft Position System Variation compensating values stored in the PCM, DTC P0300 may set. Refer to Diagnostic Aids for DTC P0300. The Crankshaft Position System Variation Learn Procedure should be performed if any of the following conditions are true: ^DTC P1336 is set. ^ The PCM has been replaced. ^ The engine has been replaced. ^ The crankshaft has been replaced. ^ The crankshaft harmonic balancer has been replaced. ^ The crankshaft position sensor has been replaced. Important: The scan tool Crankshaft Position System Variation Learn function will be inhibited if engine coolant temperature is less than 70°C (158°F). Allow the engine to warm to at least 70°C (158°F) before attempting the Crankshaft Position System Variation Learn Procedure. The scan tool Crankshaft Position System Variation Learn function will be inhibited if any Powertrain DTCs other than DTC P1336 are set before or during the Crankshaft Position System Variation Learn Procedure. Diagnose and repair any DTCs if set. Refer to applicable DTCs. The Crankshaft Position System Variation Learn function will be inhibited if the PCM detects a malfunction involving the camshaft position signal circuit, the 3X reference circuit, or the 24X reference circuit. If a malfunction has been indicated, refer to the following list to diagnose the system or sensor. ^ DTC P0336 Crankshaft Position (CKP) Sensor Circuit. ^ DTC P0341 Camshaft Position (CMP) Sensor Performance. ^ DTC P1374 Crankshaft Position (CKP) High to Low Resolution Frequency Correlation. The scan tool Crankshaft Position System Variation Learn function will not be enabled until engine coolant temperature reaches 70°C (158°F) Selecting the crankshaft position system variation learn procedure on the scan tool will command the PCM to enable CKP system variation learn fuel cutoff and allow the crankshaft position system variation compensating values to be stored in the PCM. The PCM must detect an engine speed of 5150 RPM (CKP system variation learn fuel cutoff) during the Crankshaft Position System Variation Learn Procedure to store the crankshaft position system variation compensating values and complete the procedure. Important: Block the drive wheels when performing the Crankshaft Position System Variation Learning Procedure in order to prevent personal injury. Set the vehicle parking brake when instructed by the scan tool. Quickly increase the accelerator pedal until wide open throttle is reached and hold. During the learn procedure the PCM will automatically control injector operation, when the RPM has reached a certain RPM the PCM will stop the fuel injectors from pulsing until the learn procedure is finished. When the PCM has learned the crankshaft variation the fuel injectors will return to normal operation and the engine will begin to accelerate again. Release the throttle when the engine reaches the second fuel cut off. Leaving the throttle open during the fuel cut off learn procedure will allow the engine to decel at an even rate. 1. Block the drive wheels. 2. Ensure the hood is closed. 3. Start the engine and allow engine coolant temperature to reach at least 70°C (158°F) 4. Turn OFF the ignition. 5. Select and enable the Crankshaft Position System Variation Learn Procedure with the scan tool. 6. Set the parking brake when instructed by the scan tool. 7. Start the vehicle. 8. Apply and hold the service brake pedal firmly. 9. Ensure the transaxle is in park. 10. Steadily increase the accelerator pedal until the fuel cutoff is reached at 5150 RPM and hold. Release the accelerator pedal after the second fuel cutoff has been reached. 11. The crankshaft position system variation compensating values are learned when the RPM decreases back to idle. If the procedure terminates. 12. Observe DTC status for DTC P1336. 13. If the scan tool indicates that DTC P1336 ran and passed, the Crankshaft Position System Variation Learn Procedure is complete. If the scan tool indicates DTC P1336 failed or not run, determine if other DTCs have set. If DTCs other than P1336 are not set, repeat the Crankshaft Position System Variation Learn Procedure as necessary. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5080 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement (7X) REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Crank steering wheel fully to the left. 3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting. 4. Remove the right tire and wheel. 5. Disconnect the sensor electrical connector. 6. Remove the attaching bolt/screw. 7. Remove the sensor from engine. 8, Inspect for wear, cracks, or leakage if the sensor is not being replaced. INSTALLATION PROCEDURE 1. Lubricate the O-ring with clean engine oil before installation and replace if damaged. 2. Install the sensor to the block. 3. Reinstall the sensor attaching bolt. Tighten Tighten the bolt to 11 N.m (97 lb in). 4. Connect the sensor electrical connector. 5. Install the right tire and wheel. 6. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5081 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement (24X) REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the serpentine drive belt from crankshaft pulley. 3. Raise the vehicle on hoist. Refer to Lifting and Jacking the Vehicle in General Information 4. Remove the crankshaft harmonic balancer. 5. Note the routing of sensor harness before removal. 6. Remove the harness retaining clip with bolt (1). 7. Disconnect the sensor electrical connector. 8, Remove the sensor bolts (4). 9. Remove the sensor. INSTALLATION PROCEDURE 1. Install the 24X crankshaft position sensor with bolts (4) and route harness as noted during removal. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the harness retaining clip with bolt (3). Tighten Tighten the bolts to 10 N.m (88 lb in). 3. Connect the sensor electrical connector. 4. Reinstall the balancer on the crankshaft. 5. Lower vehicle. 6. Reinstall the serpentine drive belt. 7. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Data Link Connector (DLC) Data Link Connector: Locations Data Link Connector (DLC) Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Data Link Connector (DLC) > Page 5086 Locations View On the bottom of the instrument panel, to the right of the steering column. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Data Link Connector (DLC) > Page 5087 Data Link Connector: Locations Splice Pack - SP205 (Star Connector) Locations View Next to the LH IP accessory wiring junction block wiring harness, taped on harness. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 5088 Data Link Connector (DLC) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 5089 Data Link Connector: Description and Operation The provision for communicating with the control module is the DATA LINK Connector (DLC). The connector is usually located under the instrument panel. The DLC is used to connect to a scan tool. Some common uses of the scan tool are listed below: ^ Identifying stored Diagnostic Trouble Codes (DTCs). ^ Clearing DTCs ^ Performing output control tests. ^ Reading serial data. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Description and Operation EGR Valve Position Sensor: Description and Operation The Exhaust Gas Recirculation (EGR) pintle position sensor is an integral part of the EGR valve assembly. This sensor can not be serviced separately from the EGR valve assembly. EGR Pintle Position Sensor The PCM monitors the EGR valve pintle position input to ensure that the valve responds properly to commands from the PCM and to detect a fault if the pintle position sensor and control circuits are open or shorted. If the PCM detects a pintle position signal voltage outside the normal range of the pintle position sensor, or a signal voltage that is not within a tolerance considered acceptable for proper EGR system operation, the PCM will set DTC P1404 EGR valve stuck open. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Powertrain Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 5097 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 5098 Powertrain Control Module: Locations Locations View RH side of the engine compartment, forward of the strut tower, inside air box. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5101 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5102 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5103 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5104 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5105 Powertrain Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5106 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5107 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5108 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5109 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5110 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5111 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5112 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5113 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5114 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5115 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5116 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5117 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5118 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5119 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5120 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5121 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5122 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5123 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5124 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5125 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5126 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5127 Powertrain Control Module: Connector Views Powertrain Control Module Connector C1 End View (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5128 Powertrain Control Module Connector C1 End View (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5129 Powertrain Control Module Connector C2 End View (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5130 Powertrain Control Module Connector C2 End View (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > EEPROM Programming Powertrain Control Module: Service and Repair EEPROM Programming 1. The ignition is ON. 2. If the PCM fails to program, inspect the Techline equipment for the latest software version. 3. Attempt to program the PCM. If the PCM still cannot be programmed properly, replace the PCM. The replacement PCM must be programmed. Functional Check 1. Perform A Powertrain On Board Diagnostic (OBD) System Check. 2. Start the engine and let the engine run for one minute. 3. Use the scan tool in order to scan for the DTCs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > EEPROM Programming > Page 5133 Powertrain Control Module: Service and Repair PCM Replacement/Programming NOTE: In order to prevent possible Electrostatic Discharge damage to the PCM, Do Not touch the connector pins or the soldered components on the circuit board. Service of the PCM should normally consist of either replacement of the PCM or EEPROM programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if it is the correct part. If it is, remove the faulty PCM and install the new service PCM. NOTE: Turn the ignition OFF when installing or removing the PCM connectors and disconnecting or reconnecting the power to the PCM (battery cable, PCM pigtail, PCM fuse, jumper cables, etc.) in order to prevent internal PCM damage. IMPORTANT: When replacing the production PCM with a service PCM, it is important to transfer the broadcast code and production PCM number to the service PCM label. Do not record on PCM cover. This will allow positive identification of PCM parts throughout the service life of the vehicle. THE SERVICE PCM EEPROM WILL NOT BE PROGRAMMED. DTC P0602 indicates the EEPROM is not programmed or has malfunctioned. Removal Procedure CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Disconnect the IAT sensor electrical connector. 3. Remove the 3 bolts from the inner fender brace and remove the brace. 4. Loosen the clamps securing the air intake duct/MAF sensor to the air cleaner housing and throttle body. 5. Carefully remove the air intake duct/MAF sensor from the throttle body and air cleaner housing (1). 6. Remove the 2 screws (2) from the 2 air cleaner housing sections. 7. Remove the air cleaner housing cover assembly. 8. Without disconnecting the PCM connectors, remove the PCM (4) and harness from the PCM housing (3). 9. Disconnect the PCM connectors. Installation Procedure 1. Connect the PCM connectors. 2. Carefully install the PCM (4) and harness into the PCM housing (3). 3. Install the air cleaner housing cover assembly (1). 4. Install the 2 screws to the 2 air cleaner housing sections. 5. Carefully install the air intake duct to the throttle body and air cleaner housing. 6. Tighten the clamp securing the air intake duct to the air cleaner housing. 7. Position the inner fender brace and reinstall the 3 bolts. 8. Connect the Negative Battery Cable. 9. If a replacement PCM is being installed, program the PCM. The replacement PCM will NOT allow Secondary AIR Pump operation until a total of 10 miles have accumulated. 10. If a replacement PCM is being installed, perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Mounted in the fuel tank. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 5137 Fuel Level Sensor: Description and Operation The fuel level sensor consists of the following components: float, the wire float arm, and the ceramic resistor card. The fuel level sensor is mounted on the modular fuel sender assembly and is used as an input to the PCM. The PCM uses this information as a fuel level input for Various diagnostics. In addition the PCM transmits the fuel level over the Class II communication circuit to the IP cluster. This information is used for the IP fuel gauge, and low fuel warning indicator if applicable. Fuel Level Sensor The Fuel Level Sensor(4) is mounted on the Modular Fuel Sender Assembly(s). The PCM uses the fuel level input for various diagnosis including the EVAP System. In addition the PCM transmits the fuel level over the Class II communication circuit to the IP Cluster. The low fuel level message may not appear if other messages are being commanded, such as the rear deck lid, driver or passenger doors ajar. Ensure that all doors and compartment lids are completely closed. For further information regarding the Fuel Level Sensor refer to Fuel Metering Modes of Operation. See: Fuel Delivery and Air Induction/Description and Operation/Fuel Metering/Fuel Metering Modes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 5138 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure. See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair 2. Remove the modular fuel sender assembly. 3. Remove the fuel level sensor (5) from the modular fuel sender. INSTALLATION PROCEDURE 1. Reinstall the fuel level sensor (5) to modular fuel sender. 2. Reinstall the fuel sender assembly. 3. Tighten the fuel filler cap. 4. Reconnect the negative battery cable. 5. Inspect for fuel leaks. 5.1. Turn the ignition ON for 2 seconds 5.2. Turn the ignition OFF for 10 seconds. 5.3. Turn the ignition ON. 5.4. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Fuel Tank Pressure (FTP) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Fuel Tank Pressure Sensor - 1 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor - 1 The Fuel Tank Pressure (FTP) sensor measures the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The sensor mounts at the top of the fuel tank sending unit. The PCM supplies a 5 volt reference voltage and ground to the sensor. The sensor provides a signal voltage between 0.1-4.9 volts to the PCM. When the air pressure in the fuel tank is equal to the outside air pressure, such as when the fuel fill cap is removed, the output voltage of the sensor will measure 1.3-1.7 volts. When the air pressure in the tank is 4.5 inches H20 (1.25 kPa), the sensor output voltage should measure 0.5 ± 0.2 volts (1.25 kPa). The sensor voltage increases to approximately 4.5 volts at 14 inches of H2O (-3.75 kpa). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Fuel Tank Pressure Sensor - 1 > Page 5144 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor - 2 Fuel Tank Pressure Sensor The Fuel Tank Pressure Sensor(6) is mounted on top the Modular Fuel Sender Assembly(S). The PCM uses the fuel tank pressure input for the EVAP System. The PCM supplies a 5 volt reference to the sensor and a sensor return (ground). The PCM monitors the signal circuit from the sensor with a voltage range from 0.1 volts to 4.9 volts. When the pressure inside the fuel tank is totally vented the pressure is equal to atmospheric pressure or approximately 1.3-1.7 volts. When the tank is pressurized the voltage can reach more than 4.5 volts. For further information regarding the Fuel Tank Pressure Sensor refer to Fuel Metering Modes of Operation, and EVAP Control System Operation Description. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Fuel Tank Pressure Sensor - 1 > Page 5145 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor - 3 Fuel Tank Pressure Sensor The Fuel Tank Pressure (FTP) sensor measures the difference between the air pressure, or vacuum, in the fuel tank and the outside air pressure. The sensor mounts at the top of the fuel tank sending unit. The PCM supplies a 5 volt reference voltage and ground to the sensor. The sensor provides a signal voltage between 0.1-4.9 volts to the PCM. When the air pressure in the fuel tank is equal to the outside air pressure, such as when the fuel fill cap is removed, the output voltage of the sensor will measure 1.3-1.7 volts. When the air pressure in the tank is 1.25 kPa (4.5 inches Hg), the sensor output voltage should measure 1.25 kPa (approx 0.5 volts). The sensor voltage increases to approximately 4.5 volts at -3.75 kPa (14 inches of Hg). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 5146 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the spare tire cover, the jack, and the spare tire. 3. Remove the trunk liner. 4. Remove the 7 nuts retaining the fuel sender access panel. 5. Remove the fuel sender access panel. 6. Disconnect the electrical connector from the fuel tank vapor pressure sensor. 7. Remove the fuel tank vapor pressure sensor (7) from modular fuel sender assembly. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 5147 1. Reinstall the new fuel tank vapor pressure sensor (7) to modular fuel sender. 2. Connect the electrical connector to fuel tank vapor pressure sensor 3. Reinstall the fuel sender access panel. 4. Reinstall the 7 nuts retaining the fuel sender access panel. Tighten Tighten the fuel sender access panel nuts to 10 N.m (88 lb in) 5. Reinstall the trunk liner. 6. Reinstall the spare tire, the jack, and the spare tire cover. 7. Reconnect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control Motor (IAC): Specifications Idle Air Control Valve Attaching Screws 3 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations > Idle Air Control (IAC) Valve Idle Air Control Motor (IAC): Locations Idle Air Control (IAC) Valve Left Front Of Engine Top of the engine, front of the throttle assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations > Idle Air Control (IAC) Valve > Page 5153 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions Idle Air Control Motor (IAC): Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5156 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5157 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5158 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5159 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5160 Idle Air Control Motor (IAC): Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5161 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5162 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5163 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5164 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5165 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5166 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5167 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5168 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5169 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5170 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5171 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5172 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5173 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5174 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5175 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5176 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5177 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5178 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5179 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5180 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5181 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5182 Idle Air Control Valve Motor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5183 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 5184 Idle Air Control Motor (IAC): Description and Operation The purpose of the Idle Air Control (IAC) valve is to control engine idle speed, while preventing stalls due to changes in engine load. The AC valve, mounted in the throttle body, controls bypass air around the throttle plate. By moving a conical valve, known as a pintle, in (to decrease air flow) or out (to increase air flow), a controlled amount of air can move around the throttle plate. If RPM is too low, the PCM will retract the IAC pintle, resulting in more air being bypassed around the throttle plate to increase RPM. If RPM is too high, the PCM will extend the IAC pintle, allowing less air to be bypassed around the throttle plate, decreasing RPM. The IAC pintle moves in small steps called counts. During idle, the proper position of the AC pintle is calculated by the PCM based on battery voltage, coolant temperature, engine load, and engine RPM. If the RPM drops below a specified value, and the throttle plate is closed (TP sensor voltage is between 0.20-0.74), the PCM senses a near stall condition. The PCM will then calculate a new IAC pintle position to prevent stalls. If the IAC valve is disconnected and reconnected with the engine running, the idle RPM will be wrong. In this case, the IAC has to be reset. The IAC resets when the key is cycled ON then OFF. When servicing the IAC, it should only be disconnected or connected with the ignition OFF in order to keep from having to reset the IAC. The position of the IAC pintle affects engine start up and the idle characteristics of the vehicle. If the IAC pintle is open fully, too much air will be allowed into the manifold. This results in high idle speed, along with possible hard starting and a lean air/fuel ratio. DTC P0507 may set. If the IAC pintle is stuck closed, too little air will be allowed in the manifold. This results in a low idle speed, along with possible hard starting and a rich air/fuel ratio. DTC P0506 may set. If the IAC pintle is stuck part way open, the idle may be high or low and will not respond to changes in engine load. The IAC valve is used to control engine idle speed, while preventing stalls due changes in engine load. For further information regarding the IAC Valve refer to Fuel Metering Modes of Operation. See: Fuel Delivery and Air Induction/Description and Operation/Fuel Metering/Fuel Metering Modes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 5185 Idle Air Control Motor (IAC): Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the electrical connector from the idle air control valve. 3. Remove the 2 idle air control valve attaching screws. 4. Remove the idle air control valve. 5. Remove the idle air control valve O-ring. INSTALLATION PROCEDURE NOTE: The IAC valve may be damaged if installed with the cone (pintle) extended more than 28 mm (1-1/8 in). Measure the distance that the valve is extended before installing a new valve. The distance from the idle air control valve motor housing to the end of the idle air control valve pintle should be less than 28 mm (1-1/8 in). Manually compressing the pintle until the extension is less than 28 mm (1-1/8 in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 5186 1. Install the new idle air control O-ring. 2. Install the idle air control valve in the intake manifold. NOTE: Refer to Fastener Notice in Service Precautions. 3. Reinstall the idle air control valve (2) attaching screws. Tighten Tighten the idle air control valve attaching screws to 3.0 N.m (27 lb in). 4. Connect the electrical connector to the idle air control valve. 5. The PCM will reset the idle air control valve whenever the ignition switch is turned ON, then OFF. Turn the ignition switch ON, then OFF. 6. Start the engine and allow the engine to reach operating temperature. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations > Data Link Connector (DLC) Information Bus: Locations Data Link Connector (DLC) Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations > Data Link Connector (DLC) > Page 5191 Locations View On the bottom of the instrument panel, to the right of the steering column. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations > Data Link Connector (DLC) > Page 5192 Information Bus: Locations Splice Pak SP205 (Star Connector) Locations View Next to the LH IP accessory wiring junction block wiring harness, taped on harness. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations > Page 5193 Information Bus: Description and Operation CLASS 2 SERIAL DATA LINK The Class 2 serial data link allows these modules to communicate data with each other: ^ Body Control Module (BCM) ^ Driver Information Center (DIC) ^ Electronic Brake Control Module (EBCM) ^ Inflatable Restraint Sensing and Diagnostic Module (SDM) ^ Instrument Panel Cluster ^ Powertrain Control Module (PCM) ^ Radio In addition, the Class 2 serial data link allows a scan tool to communicate with these modules for diagnostic and testing purposes. The Class 2 serial data link is located at the DLC connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview Begin the diagnosis of the data link communications by performing the Diagnostic System Check for the system in which the customer concern is apparent. The Diagnostic System Check will direct you to the correct procedure within the Data Link Communications section when a communication malfunction is present. Scan Tool Diagnostics Refer to scan tool manual for instructions on using can tool diagnosis. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5196 Information Bus: Reading and Clearing Diagnostic Trouble Codes With Diagnostic Scan Tool PROCEDURE A Tech II or equivalent Scan tool must be used to retrieve Diagnostic Trouble Codes (DTCs) from the PCM memory. DTCs can no longer be retrieved at the data link connector. This also eliminates the PCM function of flashing Code 12. Follow the instructions supplied by the Scan tool manufacturer in order to access and read either current and/or history DTCs. Without Diagnostic Scan Tool A Tech II or equivalent scan tool must be used to retrieve Diagnostic Trouble Codes (DTCs) from the PCM memory. DTCs can no longer be retrieved at the data link connector. This also eliminates the PCM function of flashing Code 12. Follow the instructions supplied by the scan tool manufacturer in order to access and read either current and/or history DTCs. With Diagnostic Scan Tool PROCEDURE Use a Tech II or equivalent Scan tool to clear Diagnostic Trouble Codes (DTCs) from the PCM memory. When clearing DTCs, follow the instructions supplied by the Scan tool manufacturer. NOTES: ^ Do not clear the DTCs unless directed to do so by the service information provided for each diagnostic procedure. All of the diagnostic data that was saved along with the DTC (freeze frame data and/or malfunction history records) which may be helpful for some diagnostic procedures will be erased from the memory when the DTCs are cleared. ^ Interrupting PCM battery voltage to clear DTCs is NOT recommended. Without Diagnostic Scan Tool PROCEDURE Use a Tech II or equivalent Scan tool to clear Diagnostic Trouble Codes (DTCs) from the PCM memory. When clearing DTCs, follow the instructions supplied by the Scan tool manufacturer. NOTES: ^ Do not clear the DTCs unless directed to do so by the service information provided for each diagnostic procedure. All of the diagnostic data that was saved along with the DTC (freeze frame data and/or malfunction history records) which may be helpful for some diagnostic procedures will be erased from the memory when the DTCs are cleared. ^ Interrupting PCM battery voltage to clear DTCs is NOT recommended. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5197 Information Bus: Symptom Related Diagnostic Procedures Class 2 Communication Malfunction Diagnostic Chart (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5198 Diagnostic Chart (Part 2 Of 2) CIRCUIT DESCRIPTION Modules connected to the class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within about five seconds of beginning serial data communication, DTC U1000 or U1255 is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. CONDITIONS FOR RUNNING THE DTC ^ Voltage supplied to the module is in the normal operating voltage range (approximately 9 to 16 volts). ^ Diagnostic trouble codes U1300, U1301 and U1305 do not have a current status. ^ The vehicle power mode (ignition switch position) requires serial data communication to occur. CONDITIONS FOR SETTING THE DTC At least one critical operating parameter has not been associated with an identification number within about five seconds after beginning serial data communication. ACTION TAKEN WHEN THE DTC SETS The module uses a default value for the missing parameter. CONDITIONS FOR CLEARING THE DTC ^ A current DTC U1000 or U1255 will clear when all critical operating paremeters for the module have been associated with an identification number or at the end of the current ignition cycle. ^ A history DTC U1000 or U1255 will clear upon receipt of a scan tool Clear DTCs command. DIAGNOSTIC AIDS When a malfunction (such as an open fuse to a module) occurs while modules are communicating, a Lost Communication DTC is set as a current DTC. When the modules stop communicating (ignition is turned OFF) the current Lost Communication DTC is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so DTC U1OOO or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only DTC U1000 or U1255 is set. TEST DESCRIPTION The number(s) below refer to the step number(s) on the diagnostic table. 1. A Lost Communication with XXX DTC with a history status may indicate the cause of U1000 or U1255. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5199 2. The module(s) which is not communicating is the likely cause of U1OOO or U1255 being set. The following modules communicate on the class 2 serial data circuit: ^ PCM ^ Auxiliary Power Connector ^ Radio ^ EBCM ^ SDM ^ IPC ^ Remote CD Player (if equipped with UQ3) ^ DIC ^ BCM 5. The module which was not communicating may have set Lost Communication with XXX DTCs for those modules that it was monitoring. 6. The module which was not communicating may have set Lost Communication with XXX DTCs for those modules that it was monitoring. 7. The module which was not communicating may have set Lost Communication with XXX DTCs for those modules that it was monitoring. 11. The modules which can communicate indicate the module which cannot communicate. You must clear the DTC from these modules to avoid future misdiagnosis. 13. If all modules are communicating, the module which set U1000 or U1255 may have done so due to some other condition. 14. The module which set U1000 or U1255 is the likely cause of the malfunction. Scan Tool Does Not Communicate With Class 2 Device Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5200 Diagnostic Chart (Part 1 Of 5) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5201 Diagnostic Chart (Part 2 Of 5) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5202 Diagnostic Chart (Part 3 Of 5) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5203 Diagnostic Chart (Part 4 Of 5) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5204 Diagnostic Chart (Part 5 Of 5) CIRCUIT DESCRIPTION Modules connected to the class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. Connecting a scan tool to the DLC allows communication with the modules for diagnostic purposes. Diagnostic trouble codes (DTCs) may be set due to this symptom and during this diagnostic procedure. Complete the diagnostic procedure in order to ensure all the DTCs are diagnosed and cleared from memory. DIAGNOSTIC AIDS ^ The BCM detects that the ignition is ON and sends the appropriate power mode message to the other module. Therefore, the BCM must be connected to the DLC for any other module to communicate with the scan tool. ^ When the class 2 serial data circuit is shorted to ground, U1300 or U1305 will be set. Refer to DTC U1300 Class 2 Data Link Low or DTC U1305 Class 2 Data Link Low or High. ^ When the class 2 serial data circuit is shorted to B+ U1301 or U1305 will be set. Refer to DTC U1301 Class 2 Data Link High or DTC U1305 Class 2 Data Link Low or High. TEST DESCRIPTION The number(s) below refer to the step number(s) on the diagnostic table. 2. A partial malfunction in the class 2 serial data circuit uses a different procedure from a total malfunction of the class 2 serial data circuit. The following modules communicate on the class 2 serial data circuit: ^ PCM ^ Auxiliary Power Drop Connector ^ Radio ^ EBCM ^ SDM ^ IPC ^ Remote CD Player (if equipped with UQ3) ^ DIC ^ BCM 3. The following DTC's may be retrieved with a history status, but are not the cause of the present condition. ^ U1300 ^ U1301 ^ U1305 4. A State of Health DTC with a history status may be present along with a U1OOO or U1255 having a current status. This indicates that the malfunction occured when the ignition was ON. 5. Data link connector terminals 2 and 5 provide the connection to the class 2 serial data circuit and the signal ground circuit respectively. 7. A poor connection at terminal A would cause this condition but will not set a DTC. 8. An open in the class 2 serial data circuit between the DLC and splice pack SP 205 will prevent the scan tool from communicating with and Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5205 module. This condition will not set a DTC. 9. The class 2 serial data circuit is shorted to voltage or ground. The condition may be due to the wiring or due to a malfunction in one of the modules. When testing the wire for a short, make sure there is not a module connected to the wire being tested. This test isolates the BCM class 2 serial data circuit. 11. The BCM detects that the ignition is ON and sends the appropriate power mode message to the other modules. Therefore, the BCM must remain connected to the DLC for any other module to communicate with the scan tool. This test isolates the PCM class 2 serial data circuit. 13. This test isolates the Auxiliary Power Drop Connector class 2 serial data circuit. 15. This test isolates the Radio class 2 serial data circuit. 17. This test isolates the EBCM class 2 serial data circuit. 19. This test isolates the SDM class 2 serial data circuit. 21. This test isolates the Instrument Cluster class 2 serial data circuit. 23. This test isolates the Remote CD Player class 2 serial data circuit. 25. This test isolates the DIC class 2 serial data circuit. 29. If there are no current DTC's that begin with a "U", the communication malfunction has been repaired. 30. The communication malfunction may have prevented diagnosis of the customer complaint. For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Scan Tool Does Not Power Up Diagnostic Chart CIRCUIT DESCRIPTION The data link connector (DLC) provides operating power for the scan tool at terminal 16 (battery positive voltage) and at terminal 4 (ground). The DLC provides the class 2 serial data signal at terminal 2 and signal ground at terminal 5. The scan tool will power up with the ignition off. Many modules, however, will not communicate unless the Body Control Module (BCM) detects that the ignition is on and sends the appropriate power mode message. TEST DESCRIPTION The number(s) below refer to the step number(s) on the diagnostic table. 1. The CLSTR/BCM fuse supplies power to terminal 16 of the DLC. 4. The battery positive voltage and ground circuits of the DLC are functioning properly. The malfunction must be due to the scan tool. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5206 Information Bus: Scan Tool Testing and Procedures Diagnostic Chart Refer to Data Link Communications Schematic, and Data Link Communications Schematic in Data Link Communications. CIRCUIT DESCRIPTION Modules connected to the Class II serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. Connecting a scan tool to the DLC allows communication with the modules for diagnostic purposes. Diagnostic Trouble Codes (DTCs) may be set due to this symptom and during this diagnostic procedure. Complete the diagnostic procedure in order to ensure all the DTCs are diagnosed and cleared from memory. DIAGNOSTIC AIDS ^ When the Class II serial data circuit is shorted to ground, U1300 or U1305 will be set. Refer to DTC U1300 Class 2 Data Link Low or DTC U1305 Class 2 Data Link Low or High. See: See: ^ When the Class II serial data circuit is shorted to battery positive voltage U1301 or U1305 will be set. Refer to DTC U1301 Class 2 Data Link High or DTC U1305 Class 2 Data Link Low or High. See: See: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications knock Sensor 19 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations Knock Sensor: Component Locations Left Front Of Engine Knock Sensor (KS) Bank 1 Lower RR of the engine, below the exhaust manifold. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations > Page 5212 Knock Sensor: Connector Locations Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations > Page 5213 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5216 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5217 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5218 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5219 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5220 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5221 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5222 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5223 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5224 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5225 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5226 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5227 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5228 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5229 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5230 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5231 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5232 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5233 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5234 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5235 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5236 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5237 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5238 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5239 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5240 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5241 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5242 Knock Sensor (KS) 1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5243 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > General Information Knock Sensor: Description and Operation General Information The knock sensor detects abnormal vibration (spark knocking) in the engine. The sensor is located on the engine block near the cylinders. The sensor produces an AC output voltage which increases with the severity of the knock. This signal voltage is input to the PCM. The PCM then adjusts the Ignition Control (IC) timing to reduce spark knock. DTC P0325 Knock Sensor (KS) Circuit DTC P0327 Knock Sensor (KS) Circuit are designed to diagnose the PCM, the knock sensor, and related wiring, so problems encountered with the KS system should set a DTC. Refer to Knock Sensor (KS) System Description description of the knock sensor system. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > General Information > Page 5246 Knock Sensor: Description and Operation Operation The knock sensor detects abnormal vibration (spark knocking) in the engine. The knock sensor is mounted in the engine block near the cylinders and produce an AC signal under all engine operating conditions. The PCM contains integrated Knock Sensor (KS) diagnostic circuitry which uses the input signals from the knock sensors to detect engine detonation. This allows the PCM to retard Ignition Control (IC) spark timing based on the amplitude and frequency of the KS signal being received. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > General Information > Page 5247 Knock Sensor: Description and Operation Purpose Knock Sensor (KS) System Description Purpose Varying octane levels in todays gasoline may cause detonation in some engines. Detonation is caused by an uncontrolled explosion (burn) in the combustion chamber. This uncontrolled explosion could produce a flame front opposite that of the normal flame front produced by the spark plug. The rattling sound normally associated with detonation is the result of two or more opposing pressures (flame fronts) colliding within the combustion chamber. Though light detonation is sometimes considered normal, heavy detonation could result in engine damage. To control spark knock, a Knock Sensor (KS) system is used. This system is designed to retard spark timing when spark knock is detected in the engine. The KS system allows the engine to use maximum spark advance for optimal driveability and fuel economy. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 5248 Knock Sensor: Testing and Inspection The PCM calculates an average voltage the knock sensor signal and takes instantaneous signal voltage readings. The PCM uses the instantaneous signal voltage reading to determine the state of the knock sensor circuitry. If the knock sensor system is operating normally, the PCM should monitor instantaneous KS signal voltage readings varying outside a voltage range above and below the calculated average voltage. The following DTCs are used to diagnose the knock sensor system: ^ If the PCM malfunctions in a manner which will not allow proper diagnosis of the KS circuits, DTC P0325 will set. ^ DTC P0327 is designed to diagnose the knock sensor, and related wiring, so problems encountered with the KS system should set a DTC. However, if no DTC was set but the KS system is suspect because detonation was the customer's complaint, use the tables for P0327 to diagnose the Detonation/Spark Knock Symptom. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 5249 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting. 3. Disconnect the knock sensor wiring harness connector from the knock sensor. 4. Remove the knock sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Do Not apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. NOTE: Refer to Fastener Notice in Service Precautions. Knock Sensor (KS) System Deascription Purpose 1. Install the knock sensor into engine block. Tighten Tighten the knock sensor to 19 N.m (14 lb ft). 2. Connect the knock sensor wiring harness connector to the knock sensor. 3. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Malfunction Indicator Lamp: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5254 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5255 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5256 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5257 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5258 Malfunction Indicator Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5259 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5260 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5261 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5262 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5263 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5264 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5265 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5266 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5267 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5268 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5269 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5270 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5271 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5272 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5273 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5274 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5275 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5276 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5277 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5278 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5279 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5280 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Malfunction Indicator Lamp (MIL) - Description Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) Description The Service Engine Soon/Malfunction Indicator Lamp (MIL) is located in the Instrument Panel (IP) Cluster. The MIL is controlled by the PCM and is used to indicate that the PCM has detected a condition that affects vehicle emissions, may cause powertrain damage, or severely impacts driveability. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Malfunction Indicator Lamp (MIL) - Description > Page 5283 Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) Operation The Malfunction Indicator Lamp (MIL) is located on the instrument panel and is displayed as CHECK ENGINE lamp. MIL Function ^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible ^ The MIL illuminates during a bulb test and a system test ^ A DTC will be stored if a MIL is requested by the diagnostic MIL Illumination ^ The MIL will illuminate with ignition ON and the engine OFF ^ The MIL will turn OFF when the engine is started ^ The MIL will remain ON if the self-diagnostic system has detected a malfunction ^ The MIL may turn OFF if the malfunction is not present ^ If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. ^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 5284 Malfunction Indicator Lamp: Service and Repair SERVICE ENGINE SOON INDICATOR If this light is on, it indicates a problem in one of the electronically monitored systems. This light does NOT come on at certain mileage intervals. There is probably a Engine Control Module (ECM) or a Body Control Module (BCM) Code set that will aid you in diagnosis. Reset Procedure The only way to get the light to go off is to clear the ECM or BCM code(s). This light can NOT be reset or shut off any other way. ECM/BCM codes should be read & repaired before clearing them. SERVICE VEHICLE SOON INDICATOR If this light is on, it indicates a problem in one of the electronically monitored systems (a non-emissions related powertrain malfunction). This light does NOT come on at certain mileage intervals. There is probably a Engine Control Module (ECM) or a Body Control Module (BCM) Code set that will aid you in diagnosis. Reset Procedure The only way to get the light to go off is to clear the ECM or BCM code(s). This light can NOT be reset or shut off any other way. ECM/BCM codes should be read & repaired before clearing them. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications Manifold Absolute Pressure (MAP) Sensor: Specifications Manifold Absolute Pressure (MAP) Sensor Retaining Bolt 3 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 5288 Manifold Absolute Pressure (MAP) Sensor: Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 5289 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions Manifold Absolute Pressure (MAP) Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5292 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5293 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5294 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5295 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5296 Manifold Absolute Pressure (MAP) Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5297 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5298 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5299 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5300 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5301 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5302 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5303 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5304 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5305 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5306 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5307 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5308 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5309 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5310 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5311 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5312 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5313 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5314 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5315 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5316 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5317 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5318 Manifold Air Pressure (MAP) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5319 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Page 5320 Manifold Absolute Pressure (MAP) Sensor: Description and Operation The Manifold Absolute Pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the PCM varies from below 2.0 volts at idle (high vacuum) to above 4.0 volts with the key ON, and the engine OFF, or at wide open throttle (low vacuum). The MAP sensor is used to determine manifold pressure changes while the linear EGR flow test diagnostic is being run, Refer to DTC P0401 Exhaust Gas Recirculation (EGR) Flow Insufficient, to determine engine vacuum level for other diagnostics and to determine Barometric Pressure (BARO). If the PCM detects a voltage that is lower than the possible range of the MAP sensor, DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage will be set. A signal voltage higher than the possible range of the sensor will set DTC P0108 Manifold Absolute Pressure (MAP) Sensor Circuit High Voltage. An intermittent low or high voltage will set DTC P1107 Manifold Absolute Pressure (MAP) Sensor Circuit Intermittent Low Voltage or DTC P1106 Manifold Absolute Pressure (MAP) Sensor Circuit Intermittent High Voltage respectively. The PCM can also detect a shifted MAP sensor. The PCM compares the MAP sensor signal to a calculated MAP based on throttle position and various engine load factors Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Page 5321 Manifold Absolute Pressure (MAP) Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the MAP sensor from the bracket. 2. Disconnect the MAP inlet vacuum hose. 3. Disconnect the MAP sensor electrical connector. INSTALLATION PROCEDURE 1. Connect the MAP sensor electrical connector. 2. Connect the inlet vacuum hose. 3. Position the MAP sensor to bracket and tighten fasteners. Tighten Tighten the MAP sensor fasteners to 3 N.m (27 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations Oil Level Sensor For ECM: Locations Front center of the engine oil pan. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 5325 Engine Oil Level Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 5329 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Heated Oxygen Sensors 41 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 5335 Locations View Heated Oxygen Sensor 1 (HO2S1) Rear of the engine, in the exhaust manifold. Heated Oxygen Sensor 2 (HO2A2) In the exhaust system, behind the catalytic converter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 5336 Oxygen Sensor: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 5337 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5340 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5341 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5342 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5343 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5344 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5345 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5346 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5347 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5348 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5349 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5350 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5351 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5352 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5353 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5354 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5355 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5356 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5357 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5358 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5359 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5360 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5361 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5362 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5363 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5364 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5365 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5366 Oxygen Sensor: Connector Views Heated Oxygen Sensor (HO2S2) 1 Heated Oxygen Sensor (HO2S2) 2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5367 Oxygen Sensor: Electrical Diagrams Schematic Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Fuel Control Heated Oxygen Sensor (HO2S 1) Oxygen Sensor: Description and Operation Fuel Control Heated Oxygen Sensor (HO2S 1) Fuel Controlled Heated Oxygen Sensor (H02S 1) The fuel control Heated Oxygen Sensor (HO2S 1) is mounted in the exhaust manifold where it can monitor the oxygen content of the exhaust gas stream. The oxygen present in the exhaust gas reacts with the sensor to produce a voltage output. This voltage should constantly fluctuate from approximately 100 mV (high oxygen content lean mixture) to 900 mV (low oxygen content rich mixture). The heated oxygen sensor voltage can be monitored with a scan tool. By monitoring the voltage output of the oxygen sensor, the PCM calculates what fuel mixture command to give to the injectors (lean mixture low HO2S voltage = rich command, rich mixture high HO2S voltage = lean command). The HO2S 1 circuit, if open, should set a DTC P0134 HO2S Circuit Insufficient Activity Sensor 1 and the scan tool will display a constant voltage between 400-500 mV. A constant voltage below 300 mV in the sensor circuit (circuit grounded) should set DTC P0131 HO2S Circuit Low Voltage Sensor 1, while a constant voltage above 800 mV in the circuit should set DTC P0132 HO2S Circuit High Voltage Sensor 1. A fault in the HO2S 1 heater circuit should cause DTC P0135 to set. The PCM can also detect HO2S response problems. If the response time of an HO2S is determined to be too slow, the PCM will store a DTC that indicates degraded HO2S performance. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Fuel Control Heated Oxygen Sensor (HO2S 1) > Page 5370 Oxygen Sensor: Description and Operation Catalyst Monitor Heated Oxygen Sensor (HO2S 2) To control emissions of Hydrocarbons (HC), Carbon Monoxide (CO), and oxides of nitrogen (NOx), a three-way catalytic converter is used. The catalyst within the converter promotes a chemical reaction which oxidizes the HG and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The PCM has the ability to monitor this process using the HO2S 1 and the HO2S 2. The HO2S 1 produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The HO2S 2 produces an output signal which indicates the oxygen storage capacity of the catalyst, this in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the HO2S 1 signal will be far more active than that produced by the HO2S 2. The catalyst monitor sensors operate the same as the fuel control sensors. Although the HO2S 2 main function is catalyst monitoring, it also plays a limited role in fuel control. If the sensor output indicates a voltage either above or below the 450 millivolt bias voltage for an extended period of time, the PCM will make a slight adjustment to fuel trim to ensure that fuel delivery is correct for catalyst monitoring. A problem with the HO2S 2 signal circuit should set DTC P0137 HO2S Circuit Low Voltage Sensor 2, DTC P0138 HO2S Circuit High Voltage Sensor 2, or DTC P0140 HO2S Circuit Insufficient Activity Sensor 2, depending on the specific condition. A fault in the heated oxygen sensor heater element or its ignition feed or ground will result in slower oxygen sensor response. This may cause erroneous Catalyst monitor diagnostic results. A fault in the HO2S 2 heater circuit should cause DTC P0141 HO2S Heater Performance Sensor 2 to set. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement (HO2S1) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement (HO2S1) TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Socket REMOVAL PROCEDURE (HO2S1) The heated oxygen sensor may be difficult to remove when engine temperature is below 48°C (120°F). Excessive force may damage threads in exhaust manifold or exhaust pipe. 1. Turn OFF the ignition. 2. Disconnect the electrical connector. IMPORTANT: A special anti seize compound is used on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine and if for any reason is to be reinstalled, the threads must have anti seize compound applied before reinstallation. 3. Using J 39194-B heated oxygen sensor socket carefully back out the heated oxygen sensor. INSTALLATION PROCEDURE (HO2S1) 1. Coat the threads of heated oxygen sensor/catalyst monitor with anti seize compound P/N 5613695, or equivalent if necessary. 2. Install the heated oxygen sensor. Tighten Tighten the HO2S 1 (Pre-catalytic converter) to 41 N.m (30 lb ft). 3. Connect the HO2S1 sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement (HO2S1) > Page 5373 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement (HO2S2) TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Socket REMOVAL PROCEDURE (HO2S2) The heated oxygen sensor may be difficult to remove when engine temperature is below 48°C (120°F). Excessive force may damage threads in exhaust manifold or exhaust pipe. 1. Turn OFF the ignition. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting. 3. Disconnect the sensor electrical connector. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine and if for any reason is to be reinstalled, the threads must have anti seize compound applied before reinstallation. 4. Using J 39194-B heated oxygen sensor socket carefully back out the heated oxygen sensor. INSTALLATION PROCEDURE (HO2S2) 1. Coat the threads of heated oxygen sensor/catalyst monitor with anti seize compound PIN 5613695, or equivalent if necessary. NOTE: Refer to Fastener Notice in Service Precautions. 2. Using J 39194-B heated oxygen sensor socket install the heated oxygen sensor. Tighten Tighten the HO2S2 to 41 N.m (30 lb ft). 3. Connect the HO2S2 sensor electrical connector. 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Body Control Module: Customer Interest BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 5383 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 Body Control Module: Customer Interest Body Control Module - MIL ON/DTCs B2647/B2648 File In Section: 08 - Body and Accessories Bulletin No.: 00-08-47-002 Date: September, 2000 Subject: Service Vehicle Soon (SVS) Message, DTC B2647 and/or B2648 Set (Replace Body Control Module) Models: 2000 Chevrolet Impala, Monte Carlo Built Prior to VIN Breakpoint Y9255551 Condition Some customers may comment about a "Service Vehicle Soon" message displayed, which may or may not store diagnostic codes (DTCs) B2647 and/or B2648. Cause The headlamp auto control ambient light sensor sends a brief voltage spike to the body control module (BCM) during engine crank, which may be detected as a fault by the BCM. This may initiate the SVS message. This voltage is considered a normal condition of the ambient light sensor. Correction Replace the body control module (BCM) to correct this condition. BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: ^ The vehicle will not be protected against theft by the Passlock(TM) system. ^ The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 5388 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (* )You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 5389 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 47. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 48. Select Set Options and press Enter. 49. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 50. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 51. Select Set Option Configuration and press Enter. 52. Press the key under the highlighted Done area of the Tech 2 display. 53. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 54. Exit back to the Main Menu screen. 55. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 56. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 57. Turn the ignition switch to OFF and wait 15 seconds. 58. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 59. The Security and Battery messages will begin toggling. 60. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 61. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 5390 62. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 63. The Security and Battery messages will begin toggling. 64. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 65. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 66. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 67. The Security and Battery messages will begin toggling. 68. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 69. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 70. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Parts Information The BCM part number has not changed, but the new BCM should have a code GMAB139 or higher on the label. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Body Control Module: All Technical Service Bulletins BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 5396 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-52-001 > Feb > 04 > Keyless Entry - BCM Set-Up Programming Body Control Module: All Technical Service Bulletins Keyless Entry - BCM Set-Up Programming Bulletin No.: 04-08-52-001 Date: February 25, 2004 INFORMATION Subject: Set-up/Programming BCM for Remote Keyless Entry (RKE) Models: 2000-2004 Chevrolet Impala, Monte Carlo In the past, when replacing the BCM on the above listed vehicles, the module had to be set-up to ensure the RKE was initiated. The RKE option RPO may not have been called out individually on the SPID label when the RKE option was part of an option package. This would often lead to this option being missed during BCM set-up and leading to an inoperative RKE feature. The new BCM, P/N 10350647, currently available, will automatically toggle the RKE function on during initiation of the module. Therefore, it is no longer necessary to turn on the RKE. Just leave it on regardless if the vehicle is equipped with RKE or not. This will prevent an incorrect set-up causing this feature to become inoperative. This new BCM will also remedy a situation where some older BCMs would not remember the horn chirp setting, short or long, after going into sleep mode. Also, this new BCM will not lock the settings until after 32 key cycles compared to 15 key cycles on older BCMs. So, if a mistake is made during the initial set-up, you can re-set the module. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 Body Control Module: All Technical Service Bulletins Body Control Module - MIL ON/DTCs B2647/B2648 File In Section: 08 - Body and Accessories Bulletin No.: 00-08-47-002 Date: September, 2000 Subject: Service Vehicle Soon (SVS) Message, DTC B2647 and/or B2648 Set (Replace Body Control Module) Models: 2000 Chevrolet Impala, Monte Carlo Built Prior to VIN Breakpoint Y9255551 Condition Some customers may comment about a "Service Vehicle Soon" message displayed, which may or may not store diagnostic codes (DTCs) B2647 and/or B2648. Cause The headlamp auto control ambient light sensor sends a brief voltage spike to the body control module (BCM) during engine crank, which may be detected as a fault by the BCM. This may initiate the SVS message. This voltage is considered a normal condition of the ambient light sensor. Correction Replace the body control module (BCM) to correct this condition. BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: ^ The vehicle will not be protected against theft by the Passlock(TM) system. ^ The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 5405 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (* )You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 5406 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 47. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 48. Select Set Options and press Enter. 49. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 50. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 51. Select Set Option Configuration and press Enter. 52. Press the key under the highlighted Done area of the Tech 2 display. 53. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 54. Exit back to the Main Menu screen. 55. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 56. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 57. Turn the ignition switch to OFF and wait 15 seconds. 58. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 59. The Security and Battery messages will begin toggling. 60. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 61. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 5407 62. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 63. The Security and Battery messages will begin toggling. 64. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 65. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 66. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 67. The Security and Battery messages will begin toggling. 68. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 69. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 70. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Parts Information The BCM part number has not changed, but the new BCM should have a code GMAB139 or higher on the label. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure Body Control Module: All Technical Service Bulletins BCM - Related Service, Theft Deterrent Relearn Procedure File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-057A Date: May, 2000 INFORMATION Subject: Body Control Module (BCM) Related Service, Theft Deterrent Re-Learn Procedure Models: 2000 Chevrolet Impala, Monte Carlo This bulletin is being revised to update the service procedure and the labor time information. Please discard Corporate Bulletin Number 99-06-O4-057 (Section 6 - Engine/Propulsion System). BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: - The vehicle will not be protected against theft by the Passlock(TM) system. - The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 5412 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (*) You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 5413 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. 47. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 48. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 49. Select Set Options and press Enter. 50. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 51. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 52. Select Set Option Configuration and press Enter. 53. Press the key under the highlighted Done area of the Tech 2 display. 54. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 55. Exit back to the Main Menu screen. 56. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 57. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 58. Turn the ignition switch to OFF and wait 15 seconds. 59. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 60. The Security and Battery messages will begin toggling. 61. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 62. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 63. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 64. The Security and Battery messages will begin toggling. 65. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 66. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 67. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 5414 release the ignition switch to the RUN position (the engine will not crank). 68. The Security and Battery messages will begin toggling. 69. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 70. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 71. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N4800 Computer (Control), Body - 1.1 hrs Replace and Program Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn Body Control Module: All Technical Service Bulletins BCM - Related Service. Theft Deterrent Relearn File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-057 Date: November, 1999 INFORMATION Subject: Body Control Module (BCM) Related Service, Theft Deterrent Re-Learn Procedure Models: 2000 Chevrolet Impala, Monte Carlo BCM replacement requires that a programming function be performed. If the BCM is not properly programmed, the vehicle may not start because the Theft Lock System will be enabled. Important: If the module is not properly programmed within twenty (20) key cycles (including the VIN), the module will lock and programming will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reprogrammed. When replacing the BCM, a critical component of the procedure requires a programming of the BCM. To program the BCM, follow all of the steps in the procedure listed. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "setup new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: - The vehicle will not be protected against theft by the Passlock(TM) system. - The engine will not crank or start. Programming of the BCM requires the use of the Tech 2 scan tool. 1. Insure that the key (or ignition) switch is in the LOCK position with the ignition off. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the key to the ON position. 4. The following items all refer to the Tech 2 scan tool inputs: ^ Select Diagnostics and answer the questions when prompted by the Tech 2. ^ Select Body Control Module (BCM). ^ Select Special Functions. ^ Select New VIN and input the required data. ^ Exit back to the Special Functions menu. 5. Select BCM Programming. 6. Press the YES key when the following message is displayed: Do you want to setup a body control module? 7. The Tech 2 will then display the following message: Now setting up the New Body Control Module. 8. When the BCM has been setup successfully, the Tech 2 will display this message: Body Control Module setup is complete. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 5419 THIS MEANS THAT THE TECH 2 HAS SET THE BCM TO ACCEPT THE CORRECT INFORMATION. THIS IS NOT THE END OF THE PROGRAMMING PROCEDURE. 9. Exit back to the Special Functions menu. 10. Select Set Options. 11. Input all of the required data as prompted by the Tech 2. 12. Exit back to the Special Functions menu. 13. Select Option Configuration. 14. Input all of the required data as prompted by the Tech 2. 15. When the BCM, VIN, Point of Sale and option configuration have been entered, proceed with the Theft Deterrent Re-Learn Procedure. IF THE TECH 2 DISPLAYS "UNABLE TO PROGRAM THE BCM", THE BCM IS LOCKED. TWENTY KEY CYCLES HAVE OCCURRED SINCE THE MODULE WAS INSTALLED AND VOLTAGE WAS SUPPLIED TO THE MODULE SO THE MODULE MUST BE REPLACED AND THIS PROCEDURE MUST BE REPEATED IN ITS ENTIRETY. Important: Programming of the BCM removes any personalization settings the customer may have previously set. Inform the customer the personalization settings will have to be reset. Theft Deterrent Re-Learn Important: Perform the Theft Deterrent Re-Learn Procedure when one or more of the following conditions has occurred. - The BCM has been replaced or re-programmed (Set-up) (Configured). - The ignition key cylinder assembly has been replaced. The Theft Deterrent Re-Learn Procedure can be accomplished two different ways depending on the equipment you have available. ^ Using The Techline equipment and the Tech 2 scan tool. ^ Without Techline Equipment of any kind. This procedure takes 30 minutes and must not be shortened. USING TECHLINE EQUIPMENT AND THE TECH 2 SCAN TOOL 1. If you disconnected the scan tool from the DLC, perform the following 3 steps. If it is still connected, proceed to step 5. 2. Ensure that the key (or ignition) switch is in the LOCK position with the ignition off. 3. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 4. Turn the key to the ON position. 5. From the Main Menu screen of the Tech 2, select Service Programming. 6. Enter the requested information. 7. Select Request Info. 8. When the Tech 2 finishes gathering the information, disconnect the Tech 2 from the DLC. 9. Connect the Tech 2 to the Techline terminal. 10. Select Service Programming System (SPS). 11 Select Terminal to Tech 2 programming. 12. Select Done. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 5420 13. Follow the instructions displayed on the Techline terminal for hand-held communications set-up screen. 14. Select Theft Module Re-Learn. 15. Select program at the summary screen. The terminal will now download information into the Tech 2. 16. Disconnect the Tech 2 from the Techline terminal. 17. Re-connect the Tech 2 to the DLC. 18. At the Scan Tool Main Menu, select Service Programming. 19. Answer the Tech 2 question. 20. Select Re-Learn. 21. The PCM and BCM are now prepared for the Re-Learn procedure to begin. 22. An internal security timer will now start. The security timer is 10 minutes in duration. Important: During this 10 minute period, the scan tool must NOT be disconnected from the vehicle. Does the Tech 2 display any kind of message telling you to proceed? 23. Turn the ignition switch to the OFF position. 24. Start the engine. The engine should start and continue to run. 25. The Theft Re-Learn procedure is complete. Look for any DTCs which may have been set during this procedure. If codes were set, clear them now. Remove the Tech 2 from the vehicle. WITHOUT TECHLINE EQUIPMENT OF ANY KIND This procedure takes 30 minutes and must not be shortened. 1. Ensure that the battery is fully charged before starting this procedure. 2. Turn the ignition switch to the OFF position. 3. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 4. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 5. Turn the ignition switch to the OFF position for 5 seconds. 6. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 7. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 8. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 9. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 10. Turn the ignition switch to the OFF position for 5 seconds. 11. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will now start. 12. Using the Tech 2, look for a Clear All Trouble Codes (DTCs). Warranty Information For vehicles repaired under warranty, use: Operation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 5421 Labor Description Labor Time N4800 Computer (Control), Body - 0.7 hr Replace and Program Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON Coolant Level Sensor: All Technical Service Bulletins Instruments - Low Coolant Indicator Always ON Bulletin No.: 04-06-02-007 Date: August 11, 2004 TECHNICAL Subject: Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination) Models: 2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue Condition Some customers may comment that the low engine coolant level indicator is always illuminated. Cause The cause of this condition may be due to engine oil contaminating the coolant. Possible sources of oil contamination are internal engine leaks, improper service procedures, or the addition of some types of anti-leak additives to the cooling system. Once in the coolant, the oil leaves deposits on the level sensor creating an insulating film. This film results in a false activation of the coolant level indicator. Correction Diagnose low coolant level system operation and check the sensor for oil contamination using the procedure listed below. Important: No coolant supplements should be used in GM cooling systems, other than what is approved and recommended by GM. The use of "aftermarket" over-the-counter sealing and cooling supplements may affect the operation of the low coolant level sensor. Discoloration of the coolant recovery bottle is normal and does not necessarily indicate that coolant contamination is present. Flush cooling system only when instructed by this bulletin. 1. Verify that the coolant is at proper level in the radiator and the coolant recovery bottle. If the coolant is low, add proper amount of 50/50 water and DEX-COOL(R) mixture. If the low coolant light operates properly, diagnose the cooling system for loss of coolant as outlined in SI. DO NOT proceed further with this bulletin. 2. Remove the low coolant level sensor. Refer to Coolant Level Module Replacement in the Engine Cooling sub-section. 3. With the key on, the engine off and the coolant level sensor disconnected from the vehicle wiring harness, observe the low coolant light: ^ Light is on - Chassis wiring or instrument cluster concern. Follow the appropriate diagnostic information in SI. ^ Light is out - Proceed to Step 4. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON > Page 5427 4. With the key off, connect the coolant level sensor into the vehicle's wiring harness. Connect a ground wire (1) to the battery negative terminal. Using a sharp probe (3) attached to the ground wire, ground the coolant sensor probe (2) as shown in the illustration. Make sure a good contact is made. With the key on and the engine off, observe the low coolant light for at least 15 seconds. ^ Light is on - Replace the low coolant sensor and re-check system operation. ^ Light is out - Proceed to Step 5. 5. Using a small wire brush or emery cloth, polish the low coolant level sensor probe to remove any film or oxidation. The probe should be a bright brass color when finished. Use Brake Parts Cleaner to flush removed deposits from the low coolant sensor probe. Re-install the low coolant sensor into the vehicle and proceed to Step 6. 6. Flush the cooling system and install new DEX-COOL(R) mixture as outlined in the SI. Check the vehicle's warranty history to determine if any engine gasket had recently been changed. If there has not been a recent gasket replacement, locate and repair the source of the engine oil contamination. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON > Page 5428 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON > Page 5434 4. With the key off, connect the coolant level sensor into the vehicle's wiring harness. Connect a ground wire (1) to the battery negative terminal. Using a sharp probe (3) attached to the ground wire, ground the coolant sensor probe (2) as shown in the illustration. Make sure a good contact is made. With the key on and the engine off, observe the low coolant light for at least 15 seconds. ^ Light is on - Replace the low coolant sensor and re-check system operation. ^ Light is out - Proceed to Step 5. 5. Using a small wire brush or emery cloth, polish the low coolant level sensor probe to remove any film or oxidation. The probe should be a bright brass color when finished. Use Brake Parts Cleaner to flush removed deposits from the low coolant sensor probe. Re-install the low coolant sensor into the vehicle and proceed to Step 6. 6. Flush the cooling system and install new DEX-COOL(R) mixture as outlined in the SI. Check the vehicle's warranty history to determine if any engine gasket had recently been changed. If there has not been a recent gasket replacement, locate and repair the source of the engine oil contamination. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 04-06-02-007 > Aug > 04 > Instruments - Low Coolant Indicator Always ON > Page 5435 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Body Control Module: Component Locations Locations View LH side of the instrument panel, above parking brake. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 5438 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5441 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5442 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5443 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5444 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5445 Body Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5446 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5447 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5448 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5449 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5450 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5451 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5452 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5453 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5454 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5455 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5456 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5457 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5458 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5459 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5460 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5461 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5462 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5463 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5464 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5465 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5466 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5467 Body Control Module: Connector Views Body Control Module, C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5468 Body Control Module, C2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5469 Body Control Module, C3 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5470 Body Control Module: Electrical Diagrams Body Control Module Schematics: Door Lock Switches, LH Front Door Lock Assembly Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5471 Body Control Module Schematics: DRL Relay, Backup Relay And Ambient Light Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5472 Body Control Module Schematics: Headlamp Switch, Ignition Key Alarm Switch, Surveillance Switch And Park Brake Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5473 Body Control Module Schematics: Headlamp Dimmer Switch, Headlamp Relay, Parklamp Relay Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5474 Body Control Module Schematics: HORN Relay FOG LP Relay And Fog Lamp Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5475 Body Control Module Schematics: Interior Lights (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5476 Body Control Module Schematics: Interior Lights (Part 2 of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5477 Body Control Module Schematics: Power, Grounds and RAP Relay Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5478 Body Control Module Schematics: Brake Transaxle Shift Interlock Control, Rear Compartment Lid Release And Remote Control Door Lock Receiver Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5479 Body Control Schematics: Rear Defog Relay, Door Lock Cylinder Switches Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5480 Body Control Module Schematics: RF And Rear Door Lock Assemblys Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5481 Body Control Module Schematics: SEO Rear Compartment Lid Relay Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5482 Body Control Module Schematics: Traction Control Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description Body Control Module: Description and Operation Circuit Description General Information The Body Control Module (BCM) is capable of accomplishing multiple body control functions. Components directly connected to the BCM are controlled by the BCM's outputs. The BCM can control its outputs based on input information it obtains from sensors and switches that are directly connected to the BCM, or by borrowing information from other vehicle systems connected to the Class 2 serial data link. The BCM evaluates this information and controls certain body systems by commanding an output on or off. The BCM is also capable of commanding other vehicle systems to control functions that are not directly wired and/or controlled by the BCM. The BCM accomplishes this task by sending specific messages on the Class 2 serial data link. The vehicle system capable of performing such function will respond to the BCM message. The BCM performs these functions: ^ Audible warnings. ^ Interior lighting. ^ Automatic door locks. ^ Keyless entry (AUO option) ^ Passlock theft deterrent. ^ Content Theft (UA6 option) ^ Retained Accessory Power (RAP) RPO AUO, UA6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Audible Warnings ^ Key in ignition reminder. ^ Fasten seat belt reminder. ^ Fasten belts indicator control. ^ Parking brake reminder. ^ Turn signal reminder. ^ Low fuel reminder. ^ Headlamps ON reminder. ^ Last door closed locking confirmation. ^ Feature customization. Interior Lighting ^ Interior illumination control. ^ Delayed illumination. ^ Illuminated entry. ^ Exit illumination. ^ Theater dimming. ^ Keyless entry unlock illumination. ^ Inadvertent load (battery rundown) protection. Automatic Door Locks ^ All door unlock. ^ All door lock. ^ Last door closed locking. ^ Lockout prevention. ^ Lockout prevention override. ^ Shift into PARK unlock. ^ Shift out of PARK lock. ^ Remote driver door unlock. ^ Remote all door unlock. ^ Remote all door lock. Keyless Entry ^ Remote driver door unlock. ^ Remote all door unlock. ^ Remote all door lock. ^ Remote activation verification. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 5485 ^ Remote alarm. ^ Feature customization of remote activation verification. BCM Inputs The following components provide direct input to the BCM, plus other systems can use this input information in order to carry out certain functions: ^ A/C Request: Provides the BCM with a request signal to command the A/C compressor through the PCM via Class 2 serial data. ^ BCM Ground: Provides ground for BCM operation. ^ BCM Power: Provides voltage for BCM operation. ^ Courtesy Lights On: Provides the driver the ability to request illumination of the vehicle interior. ^ Crank Signal: Determines when the ignition switch is in the start position. ^ Dome Lamp Switch Input: Determines when the dome lamp switch (Headlamp Switch) is closed to request the dome lamp on. ^ Door Lock Switch: Door lock switch request to lock and unlock the vehicle doors. ^ Door Locks: Provides voltage for door lock actuator operation. ^ Door Open: Provides door ajar status. ^ Driver Door Open: Allows certain chime functions when the driver's door is open. ^ DRL Signal Low: This input provides the BCM with Information through an ambient light sensor for the DRL feature. ^ Exterior Lamps Off: Determines when the headlamp switch is in the OFF position. ^ Fog Lamp Switch input: This input provides the BCM with a request for fog lamps through a momentary switch connected to ground. ^ Headlamp Switch Input: Determines when the Headlamp switch is closed to request the headlamps on. ^ High Beam: Determines the status of the headlamp dimmer switch, so the BCM can send the instrument cluster a message, via Class 2, to turn on the high beam indicator. ^ Ignition 0 Signal: Determines when the ignition switch is in ACCESSORY, ON or START position. ^ Ignition 1 Signal: Determines when the ignition switch is in the ON and START positions. ^ Key In Ignition: Determines when the key is fully inserted in the ignition key cylinder. ^ Key Unlock: Determines the status of the door lock cylinder switches for content theft. ^ Lamp Request: This input requests the BCM to energize the Battery Rundown Protection relay after the car has been turned off and all the doors have been closed, so the interior lights can be turned on. ^ Park Brake Applied: Determines when the parking brake is applied. ^ Park Lamp Switch Input: Determines when the park lamp switch (Headlamp Switch) is closed to request the park lamps on. ^ Passlock Sensor Data: Reads the Passlock sensor security code. ^ Rear Compartment Ajar: Determines if the rear decklid is open or closed. ^ Rear Compartment Release: This input requests the BCM to open the rear compartment lid. ^ RFA Link: Provides an interface allowing the transfer of keyless entry information from the Remote Control Door Lock Receiver (RCDLR). ^ Serial Data: provides an interface with the PCM, EBCM, Radio, SDM, DIC and the IPC through the Class 2 serial data link. ^ Surveillance Switch Input: Determines when the surveillance switch is closed to request the surveillance mode. ^ Traction Control Request: This input provides the BCM with a request for Traction Control through a momentary switch connected to ground. BCM Outputs The BCM directly controls these outputs, plus other systems may request the BCM to control these outputs for certain functions: ^ All Door Lock: This output supplies voltage to the door lock actuators when the doors are commanded to lock. This output also supplies ground to all the door lock actuators when the doors are commanded to unlock. ^ Backup Lamp Relay Control: Provides ground to the Backup LP relay control circuit. ^ BTSI Solenoid Control: Provides ground to the Brake Transaxle Shift Interlock Control Solenoid. ^ Door Unlock: This output supplies voltage to the door lock actuators (except the driver door lock actuator) when the doors are commanded to unlock. This output also supplies ground to all the door lock actuators (except the driver door lock actuator) when the doors are commanded to lock. ^ Driver Door Unlock: This output supplies voltage to the driver door lock actuators when the doors are commanded to unlock. This output also supplies ground to the driver door lock actuator when the doors are commanded to lock. ^ DRL Relay Control: Provides ground to the DRL relay control circuit. ^ DRL 5 V Reference: Provides 5 Volts to the ambient light sensor. ^ Inadvertent Load Relay Control Output: Supplies ground to the battery rundown protection relay providing an inadvertent load (battery rundown) protection. ^ Fog Lamp Enable Control: Sends a ground signal to the fog lamp switch when the ignition switch on; this action enables the fog lamp switch. The fog lamps turn on when the fog lamp switch is enabled by the BCM. ^ Headlamp Relay Control: Provides ground to the Headlamp relay control circuit. ^ Horn: Sends a ground signal to the horn relay, sounding the horn for the keyless entry alarm function or the content theft system. ^ Inadvertent Relay Control: Provides ground to the Battery Rundown Protection relay control circuit. ^ Interior Dimming: Controls the voltage to the interior lights dimming system. ^ Load Management Control: Provides voltage to the Rear Defogger relay control circuit and the Heated Seats. ^ Park Lamp Relay Control: Provides ground to the Park Lamp relay control circuit. ^ Passlock Sensor Power: Provides B+ for Passlock sensor operation. ^ Passlock Sensor Ground: Provides ground to the Passlock sensor. ^ RAP Relay Control: Provides voltage to the RAP relay control feed circuit. ^ Rear Compartment Lid Release Output: Provides ground to Rear Compartment Lid Release Actuator. ^ RFA Link: Provides an interface allowing the transfer of keyless entry information to the Remote Control Door Lock Receiver (RCDLR). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 5486 ^ Serial Data: provides an interface with the PCM, EBCM, Radio, SDM, DIC and the IPC through the Class 2 serial data link. ^ Theater Dimming 1 Control: Supplies ground to activate the Footwell lamps. ^ Theater Dimming 2 Control: Supplies ground to activate the inside rear view mirror lamps, non SEO dome lamp, and the roof rail courtesy/reading lamps. BCM Wake-Up/Sleep State The BCM performs its functions in the wake-up state. The BCM enters the sleep state when active control or monitoring of system malfunctions has stopped, or when the BCM is idling. The BCM must detect certain wake-up inputs before entering the wake-up state. The BCM monitors its inputs during the sleep state, allowing the BCM to switch between the two states, awake or asleep. The BCM enters the wake-up state when receiving activity on any of these inputs: ^ I/P dimmer switch. ^ Door lock (ajar) switch. ^ Door lock switch. ^ A keyless entry system signal. ^ Inadvertent power (battery rundown) protection transition. ^ The ignition is turned to the LOCK, ACCESSORY or the ON position. The sleep state is when the BCM has stopped active control and monitoring of system functions and has become idle again. For the BCM to enter the wake-up state, the BCM must detect a wake-up condition, mentioned previously. These conditions are called wake-up inputs that cause the BCM to change from a sleep to a wake-up state and begin active control and monitoring. The BCM has the ability to monitor for these wake-up inputs in the sleep state. The BCM enters the sleep state when all of these conditions exist: ^ No activity on the Class 2 serial data link. ^ The ignition switch is in the OFF position. ^ The BCM is not commanding any outputs. ^ No delay timers are actively counting (during theft deterrent re-learn). ^ No wake-up inputs are present. Content Theft (UA6 Option) The Body Control Module features a content theft deterrent system which is designed to defer vehicle vandalism and theft. The content theft deterrent system performs these functions: ^ Flashes the headlamps ^ Sounds the horns ^ Disables fuel delivery to the engine The BCM monitors the following: ^ Status of the doors ^ Lock cylinders ^ Rear compartment lid ^ Power door locks ^ The keyless entry system The BCM operates the headlamps, horns and the theft deterrent indicator, thats in the radio, according to the mode of operation the system is in. The BCM also communicates a fuel enable signal to the Powertrain Control Module (PCM) when the system is armed. Refer to Content Theft Deterrent (CTD) Operation in Theft Deterrent for more information. RPO UA6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Miscellaneous Functions ^ BRAKE indicator lamp control: The BCM controls the state of the BRAKE indicator lamp based on the status of the parking brake switch by sending a message to the instrument cluster via the Class 2 serial data link. ^ Fog lamp enable control. The BCM controls fog lamp operation, based on the status of the ignition switch. ^ Day/night mode sensing: The BCM determines the ambient light operating mode. The BCM then communicates the information to the Instrument Cluster and Powertrain Control Module (PCM) via the Class 2 serial data link. Passlock Theft Deterrent The Passlock is a vehicle theft deterrent system. The Passlock theft deterrent system contains a Passlock sensor. The Passlock sensor is part of the ignition lock cylinder assembly. The Body Control Module (BCM) provides power and ground to the Passlock sensor. The Passlock sensor interfaces with the BCM through the Passlock detection circuit. When turning the ignition switch to the start position with the proper key, the Passlock sensor generates an analog voltage signal. This signal is sent through the Passlock detecting circuit. This analog voltage signal is of a specific value to the vehicle, and varies from vehicle to vehicle. When attempting to start the engine, the BCM compares a preset stored analog voltage value with the signal coming from the sensor. Because both values Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 5487 match, the BCM sends a fuel enable password via the Class 2 serial data link to the Powertrain Control Module (PCM). As a result, the PCM enables the crank relay, and allows fuel delivery to the engine. When attempting to start the engine by means other than using the proper key in the ignition switch, the Passlock sensor sends an analog voltage signal of a different value. The BCM compares the preset stored analog voltage value with the signal coming from the sensor. Because both values do not match, the BCM sends a fuel disable password via the Class 2 serial data link to the Powertrain Control Module (PCM). As a result, the PCM disables the crank relay, and does not allow fuel delivery to the engine. Power Requirements The BCM has three main voltage feeds and two grounds. The voltage feed circuits are used to provide power for the BCM's logic, courtesy lights, internal driver operation and the door locks. Retained Accessory Power (RAP) The Accessory Power (RAP) feature allows the operation of the following functions for 10 minutes (or until a vehicle door opens) after the ignition switch has been turned from the ON or ACCESSORY position to the LOCK position: ^ The radio ^ The power windows ^ The power sunroof (if equipped) Refer to Keyless Entry System Operation in Retained Accessory Power (RAP) for more information. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 5488 Body Control Module: Description and Operation System Operation General Information The Body Control Module (BCM) is capable of accomplishing multiple body control functions. Components directly connected to the BCM are controlled by the BCM's outputs. The BCM can control its outputs based on input information it obtains from sensors and switches that are directly connected to the BCM, or by borrowing information from other vehicle systems connected to the Class 2 serial data link. The BCM evaluates this information and controls certain body systems by commanding an output on or off. The BCM is also capable of commanding other vehicle systems to control functions that are not directly wired and/or controlled by the BCM. The BCM accomplishes this task by sending specific messages on the Class 2 serial data link. The vehicle system capable of performing such function will respond to the BCM message. The BCM performs these functions: ^ Audible warnings. ^ Interior lighting. ^ Automatic door locks. ^ Keyless entry (AUO option) ^ Passlock theft deterrent. ^ Content Theft (UA6 option) ^ Retained Accessory Power (RAP) RPO UA6, AUO: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Audible Warnings ^ Key in ignition reminder. ^ Fasten seat belt reminder. ^ Fasten belts indicator control. ^ Parking brake reminder. ^ Turn signal reminder. ^ Low fuel reminder. ^ Headlamps ON reminder. ^ Last door closed locking confirmation. ^ Feature customization. Interior Lighting ^ Interior illumination control. ^ Delayed illumination. ^ Illuminated entry. ^ Exit illumination. ^ Theater dimming. ^ Keyless entry unlock illumination. ^ Inadvertent load (battery rundown) protection. Automatic Door Locks ^ All door unlock. ^ All door lock. ^ Last door closed locking. ^ Lockout prevention. ^ Lockout prevention override. ^ Shift into PARK unlock. ^ Shift out of PARK lock. ^ Remote driver door unlock. ^ Remote all door unlock. ^ Remote all door lock. Keyless Entry ^ Remote driver door unlock. ^ Remote all door unlock. ^ Remote all door lock. ^ Remote activation verification. ^ Remote alarm. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 5489 ^ Feature customization of remote activation verification. BCM Wake-Up/Sleep State The BCM performs its functions in the wake-up state. The BCM enters the sleep state when active control or monitoring of system malfunctions has stopped, or when the BCM is idling. The BCM must detect certain wake-up inputs before entering the wake-up state. The BCM monitors its inputs during the sleep state, allowing the BCM to switch between the two states, awake or asleep. The BCM enters the wake-up state when receiving activity on any of these inputs: ^ I/P dimmer switch. ^ Door lock (ajar) switch. ^ Door lock switch. ^ A keyless entry system signal. ^ Inadvertent power (battery rundown) protection transition. ^ The ignition is turned to the LOCK, ACCESSORY or the ON position. The sleep state is when the BCM has stopped active control and monitoring of system functions and has become idle again. For the BCM to enter the wake-up state, the BCM must detect a wake-up condition, mentioned previously. These conditions are called wake-up inputs that cause the BCM to change from a sleep to a wake-up state and begin active control and monitoring. The BCM has the ability to monitor for these wake-up inputs in the sleep state. The BCM enters the sleep state when all of these conditions exist: ^ No activity on the Class 2 serial data link. ^ The ignition switch is in the OFF position. ^ The BCM is not commanding any outputs. ^ No delay timers are actively counting (during theft deterrent re-learn). ^ No wake-up inputs are present. Content Theft (UA6 Option) The Body Control Module features a content theft deterrent system which is designed to defer vehicle vandalism and theft. The content theft deterrent system performs these functions: ^ Flashes the headlamps ^ Sounds the horns ^ Disables fuel delivery to the engine The BCM monitors the following: ^ Status of the doors ^ Lock cylinders ^ Rear compartment lid ^ Power door locks ^ The keyless entry system The BCM operates the headlamps, horns and the theft deterrent indicator, thats in the radio, according to the mode of operation the system is in. The BCM also communicates a fuel enable signal to the Powertrain Control Module (PCM) when the system is armed. Refer to Content Theft Deterrent (CTD) Operation in Theft Deterrent for more information. RPO UA6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Power Requirements The BCM has three main voltage feeds and two grounds. The voltage feed circuits are used to provide power for the BCM's logic, courtesy lights, internal driver operation and the door locks. BCM Inputs The following components provide direct input to the BCM, plus other systems can use this input information in order to carry out certain functions: ^ A/C Request: Provides the BCM with a request signal to command the A/C compressor through the PCM via Class 2 serial data. ^ BCM Ground: Provides ground for BCM operation. ^ BCM Power: Provides voltage for BCM operation. ^ Courtesy Lights On: Provides the driver the ability to request illumination of the vehicle interior. ^ Crank Signal: Determines when the ignition switch is in the start position. ^ Dome Lamp Switch Input: Determines when the dome lamp switch (Headlamp Switch) is closed to request the dome lamp on. ^ Door Lock Switch: Door lock switch request to lock and unlock the vehicle doors. ^ Door Locks: Provides voltage for door lock actuator operation. ^ Door Open: Provides door ajar status. ^ Driver Door Open: Allows certain chime functions when the driver's door is open. ^ DRL Signal Low: This input provides the BCM with Information through an ambient light sensor for the DRL feature. ^ Exterior Lamps Off: Determines when the headlamp switch is in the OFF position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 5490 ^ Fog Lamp Switch input: This input provides the BCM with a request for fog lamps through a momentary switch connected to ground. ^ Headlamp Switch Input: Determines when the Headlamp switch is closed to request the headlamps on. ^ High Beam: Determines the status of the headlamp dimmer switch, so the BCM can send the instrument cluster a message, via Class 2, to turn on the high beam indicator. ^ Ignition 0 Signal: Determines when the ignition switch is in ACCESSORY, ON or START position. ^ Ignition 1 Signal: Determines when the ignition switch is in the ON and START positions. ^ Key In Ignition: Determines when the key is fully inserted in the ignition key cylinder. ^ Key Unlock: Determines the status of the door lock cylinder switches for content theft. ^ Lamp Request: This input requests the BCM to energize the Battery Rundown Protection relay after the car has been turned off and all the doors have been closed, so the interior lights can be turned on. ^ Park Brake Applied: Determines when the parking brake is applied. ^ Park Lamp Switch Input: Determines when the park lamp switch (Headlamp Switch) is closed to request the park lamps on. ^ Passlock Sensor Data: Reads the Passlock sensor security code. ^ Rear Compartment Ajar: Determines if the rear decklid is open or closed. ^ Rear Compartment Release: This input requests the BCM to open the rear compartment lid. ^ RFA Link: Provides an interface allowing the transfer of keyless entry information from the Remote Control Door Lock Receiver (RCDLR). ^ Serial Data: provides an interface with the PCM, EBCM, Radio, SDM, DIC and the IPC through the Class 2 serial data link. ^ Surveillance Switch Input: Determines when the surveillance switch is closed to request the surveillance mode. ^ Traction Control Request: This input provides the BCM with a request for Traction Control through a momentary switch connected to ground. BCM Outputs The BCM directly controls these outputs, plus other systems may request the BCM to control these outputs for certain functions: ^ All Door Lock: This output supplies voltage to the door lock actuators when the doors are commanded to lock. This output also supplies ground to all the door lock actuators when the doors are commanded to unlock. ^ Backup Lamp Relay Control: Provides ground to the Backup LP relay control circuit. ^ BTSI Solenoid Control: Provides ground to the Brake Transaxle Shift Interlock Control Solenoid. ^ Door Unlock: This output supplies voltage to the door lock actuators (except the driver door lock actuator) when the doors are commanded to unlock. This output also supplies ground to all the door lock actuators (except the driver door lock actuator) when the doors are commanded to lock. ^ Driver Door Unlock: This output supplies voltage to the driver door lock actuators when the doors are commanded to unlock. This output also supplies ground to the driver door lock actuator when the doors are commanded to lock. ^ DRL Relay Control: Provides ground to the DRL relay control circuit. ^ DRL 5 V Reference: Provides 5 Volts to the ambient light sensor. ^ Inadvertent Load Relay Control Output: Supplies ground to the battery rundown protection relay providing an inadvertent load (battery rundown) protection. ^ Fog Lamp Enable Control: Sends a ground signal to the fog lamp switch when the ignition switch on; this action enables the fog lamp switch. The fog lamps turn on when the fog lamp switch is enabled by the BCM. ^ Headlamp Relay Control: Provides ground to the Headlamp relay control circuit. ^ Horn: Sends a ground signal to the horn relay, sounding the horn for the keyless entry alarm function or the content theft system. ^ Inadvertent Relay Control: Provides ground to the Battery Rundown Protection relay control circuit. ^ Interior Dimming: Controls the voltage to the interior lights dimming system. ^ Load Management Control: Provides voltage to the Rear Defogger relay control circuit and the Heated Seats. ^ Park Lamp Relay Control: Provides ground to the Park Lamp relay control circuit. ^ Passlock Sensor Power: Provides B+ for Passlock sensor operation. ^ Passlock Sensor Ground: Provides ground to the Passlock sensor. ^ RAP Relay Control: Provides voltage to the RAP relay control feed circuit. ^ Rear Compartment Lid Release Output: Provides ground to Rear Compartment Lid Release Actuator. ^ RFA Link: Provides an interface allowing the transfer of keyless entry information to the Remote Control Door Lock Receiver (RCDLR). ^ Serial Data: provides an interface with the PCM, EBCM, Radio, SDM, DIC and the IPC through the Class 2 serial data link. ^ Theater Dimming 1 Control: Supplies ground to activate the Footwell lamps. ^ Theater Dimming 2 Control: Supplies ground to activate the inside rear view mirror lamps, non SEO dome lamp, and the roof rail courtesy/reading lamps. Miscellaneous Functions ^ BRAKE indicator lamp control: The BCM controls the state of the BRAKE indicator lamp based on the status of the parking brake switch by sending a message to the instrument cluster via the Class 2 serial data link. ^ Fog lamp enable control. The BCM controls fog lamp operation, based on the status of the ignition switch. ^ Day/night mode sensing: The BCM determines the ambient light operating mode. The BCM then communicates the information to the Instrument Cluster and Powertrain Control Module (PCM) via the Class 2 serial data link. Passlock Theft Deterrent The Passlock is a vehicle theft deterrent system. The Passlock theft deterrent system contains a Passlock sensor. The Passlock sensor is part of the ignition lock cylinder assembly. The Body Control Module (BCM) provides power and ground to the Passlock sensor. The Passlock sensor interfaces with the BCM through the Passlock detection circuit. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 5491 When turning the ignition switch to the start position with the proper key, the Passlock sensor generates an analog voltage signal. This signal is sent through the Passlock detecting circuit. This analog voltage signal is of a specific value to the vehicle, and varies from vehicle to vehicle. When attempting to start the engine, the BCM compares a preset stored analog voltage value with the signal coming from the sensor. Because both values match, the BCM sends a fuel enable password via the Class 2 serial data link to the Powertrain Control Module (PCM). As a result, the PCM enables the crank relay, and allows fuel delivery to the engine. When attempting to start the engine by means other than using the proper key in the ignition switch, the Passlock sensor sends an analog voltage signal of a different value. The BCM compares the preset stored analog voltage value with the signal coming from the sensor. Because both values do not match, the BCM sends a fuel disable password via the Class 2 serial data link to the Powertrain Control Module (PCM). As a result, the PCM disables the crank relay, and does not allow fuel delivery to the engine. Retained Accessory Power (RAP) The Retained Accessory Power (RAP) feature allows the operation of the following functions for 10 minutes (or until a vehicle door opens) after the ignition switch has been turned from the ON or ACCESSORY position to the LOCK position: ^ The radio ^ The power windows ^ The power sunroof (if equipped) Refer to Keyless Entry System Operation in Retained Accessory Power (RAP) for more information. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Body Control Module: Initial Inspection and Diagnostic Overview A Diagnostic Starting Point - Body Control System Begin the diagnosis of the body control system by performing the Diagnostic System Check for the system in which the customer concern is apparent. The Diagnostic System Check will direct you to the correct procedure for diagnosing the system and where the procedure is located. A Diagnostic System Check - Body Control System A Diagnostic System Check-Body Control System TEST DESCRIPTION The number(s) below refer to the step number(s) on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 4. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Code Setting Criteria (Fault) For Device Power Moding Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5494 Body Control Module: Reading and Clearing Diagnostic Trouble Codes With Diagnostic Scan Tool PROCEDURE A Tech II or equivalent Scan tool must be used to retrieve Diagnostic Trouble Codes (DTCs) from the PCM or BCM memory. DTCs can no longer be retrieved at the data link connector. This also eliminates the PCM function of flashing Code 12. Follow the instructions supplied by the Scan tool manufacturer in order to access and read either current and/or history DTCs. Without Diagnostic Scan Tool A Tech II or equivalent scan tool must be used to retrieve Diagnostic Trouble Codes (DTCs) from the PCM memory. DTCs can no longer be retrieved at the data link connector. This also eliminates the PCM function of flashing Code 12. Follow the instructions supplied by the scan tool manufacturer in order to access and read either current and/or history DTCs. With Diagnostic Scan Tool PROCEDURE Use a Tech II or equivalent Scan tool to clear Diagnostic Trouble Codes (DTCs) from the PCM memory. When clearing DTCs, follow the instructions supplied by the Scan tool manufacturer. NOTES: ^ Do not clear the DTCs unless directed to do so by the service information provided for each diagnostic procedure. All of the diagnostic data that was saved along with the DTC (freeze frame data and/or malfunction history records) which may be helpful for some diagnostic procedures will be erased from the memory when the DTCs are cleared. ^ Interrupting PCM battery voltage to clear DTCs is NOT recommended. Without Diagnostic Scan Tool PROCEDURE Use a Tech II or equivalent Scan tool to clear Diagnostic Trouble Codes (DTCs) from the PCM memory. When clearing DTCs, follow the instructions supplied by the Scan tool manufacturer. NOTES: ^ Do not clear the DTCs unless directed to do so by the service information provided for each diagnostic procedure. All of the diagnostic data that was saved along with the DTC (freeze frame data and/or malfunction history records) which may be helpful for some diagnostic procedures will be erased from the memory when the DTCs are cleared. ^ Interrupting PCM battery voltage to clear DTCs is NOT recommended. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5495 Body Control Module: Scan Tool Testing and Procedures Scan Tool Data Definitions Doors Battery Fd: The scan tool displays Inactive/Active. The input of the Doors Battery Fd is displayed as Active. Electronics Battery Fd: The scan tool displays Inactive/Active. The input of the Electronics Battery Fd is displayed as Active. Electronics System Gnd: The scan tool displays Inactive/Active. The input of the Electronics System Gnd is displayed as Active. Ignition 0: The scan tool displays On/Off. The input of the Ignition 0 varies on the scan tool display. Ignition 1: The scan tool displays On/Off. The input of the Ignition 1 varies on the scan tool display. Ignition 3: The scan tool displays On/Off. The input of the Ignition 3 varies on the scan tool display. Inadvert Power Relay: The scan tool displays On/Off. The input of the Inadvert Power Output varies on the scan tool display Loads Battery Fd: The scan tool displays Inactive/Active. The input of the Loads Battery Fd is displayed as Active. Loads System Gnd: The scan tool displays Inactive/Active. The input of the Loads System Gnd is displayed as Active. Theater Dim 1 Ground: The scan tool displays Inactive/Active. The input of the Theater Dim 1 Ground is displayed as Inactive. Theater Dim 2 Ground: The scan tool displays Inactive/Active. The input of the Theater Dim 2 Ground is displayed as Inactive. Scan Tool Data List Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures Body Control Module (BCM) Programming/RPO Configuration INTRODUCTION During body control module (BCM) related service, the procedures below are designated to set-up the BCM correctly. Before you start, read these procedures carefully and completely. SETUP NEW BODY CONTROL MODULE (BCM) IMPORTANT: ^ The BCM will not function properly if the Setup New BCM procedure is not performed. ^ Make sure the battery is fully charged before performing the setup procedure. ^ Make sure all disconnected devices and connectors have been reconnected ^ Perform the Theft Deterrent Re-learn procedure after successfully finishing the Setup New BCM procedure. Refer to Programming Theft Deterrent System Components in Theft Deterrent. If the Theft Deterrent Re-learn procedure is not performed after a BCM replacement, the following conditions may occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank nor start. 1. Connect a scan tool to the data link connector (DLC). 2. Turn the ignition switch ON. 3. Select Diagnostics and input all of the required data when prompted by the scan tool. 4. Select BODY CONTROL MODULE. 5. Select SPECIAL FUNCTIONS. 6. Select Setup New BCM. 7. Note, Input all of the required data when prompted by the scan tool. 8. Select Setup SDM Part Number in BCM, and follow the onscreen directions. 9. Select New VIN, and follow the onscreen directions. 10. Select Option Configuration, and follow the onscreen directions. 11. Select Point of Sale, and follow the onscreen directions. 12. Exit back to the SPECIAL FUNCTIONS menu. 13. When the BCM, VIN, Point of Sale and Option Configuration have been entered, proceed with Theft Deterrent Re-learn procedure. 14. If the scan tool displays UNABLE TO PROGRAM BCM, BCM IS SECURED, then the BCM must be replaced and this procedure must be repeated on a new BCM.. NOTE: After the above procedure has been completed, personalization of the BCM defaults to a default setting. Inform the customer that the personalization settings must be set again. IMPORTANT: After programing, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve History DTCs from all modules. 5. Clear all history DTCs General Information During Body Control Module (BCM) related service, the procedures below are designated to set-up the BCM correctly. Before you start, read these procedures carefully and completely. Theft Deterrent Re-Learn Using T-50 or T-60 1. Enter the T-50 or T-60 Service Programming System (SPS). 2. Select TERMINAL TO VEHICLE PROGRAMMING. 3. Select DONE. 4. Follow the instructions on the VEHICLE SETUP screen. 5. Select THEFT MODULE RE-LEARN. 6. Follow the instructions on the remaining screens. 7. The PCM and BCM will be prepared for re-learn. 8. A security timer will be on for approximately 10 minutes. During the 10 minute wait period, the T-50 or T-60 terminal must remain connected to the vehicle. 9. When the PCM and BCM are prepared to re-learn, turn the ignition switch off. 10. Turn the ignition switch to start. The vehicle should now start. Theft Deterrent Re-Learn W/O Scan Tool Or Techline Equipment This procedure takes approximately 30 minutes. Make sure the battery is fully charged before proceeding. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 5498 1. Turn the ignition switch off. 2. Turn the ignition switch all the way from the off to the start position, then leave it in the on position. NOTE: The engine will not crank. 3. The SECURITY will come on and stay on for at least 10 minutes. 4. Turn the ignition switch off for five seconds. 5. Repeat steps 2, 3, and 4 again for a second time. 6. Repeat steps 2, 3, and 4 again for a third time. 7. Turn the ignition switch off. 8. Turn the ignition switch all the way to the start position. The engine should now start. 9. Check for BCM Diagnostic Trouble Codes (DTCs). Theft Deterrent Re-Learn With Techline Equip & Tech 2 Scan Tool 1. Connect the Scan Tool to the Data Link Connector (DLC) on the vehicle. 2. At the Scan Tool main menu, select SERVICE PROGRAMMING. 3. Enter the requested information. 4. Select REQUEST INFO. 5. Disconnect the Scan Tool from the vehicle. 6. Connect the Scan Tool to the Techline terminal. 7. Select SERVICE PROGRAMMING SYSTEM (SPS). 8. Select TERMINAL TO TECH 2 PROGRAMMING. 9. Select DONE. 10. Follow instructions on the Techline terminal to Handheld Communications Setup screen. 11. Select THEFT MODULE RE-LEARN. 12. Select PROGRAM at the summary screen. The terminal will download information to the Scan Tool. 13. Disconnect the Scan Tool from the Techline terminal. 14. Connect the Scan Tool to the DLC on the vehicle. 15. At the Scan Tool main menu, select SERVICE PROGRAMMING. 16. Answer the question prompted by the Scan Tool. 17. Select RE-LEARN. 18. The Powertrain Control Module (PCM) and the BCM will be prepared for re-learn. 19. A security timer will be on for approximately 10 minutes. During the 10 minute wait period, Scan Tool must remain connected to the vehicle. 20. Turn the ignition switch off when the re-learn procedure is complete. 21. Turn the ignition switch to the start position. 22. The engine should start when the ignition switch is turned to the start position. 23. Disconnect the Scan Tool from the DLC. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 5499 Body Control Module: Removal and Replacement Body Control Module Replacement REMOVAL PROCEDURE IMPORTANT: You must perform the new body control module (BCM) setup when replacing the BCM. Refer to BCM Programming/RPO Configuration. 1. Disconnect the battery ground (negative) cable. 2. Remove the left instrument panel insulator. 3. Disconnect the BCM electrical connectors (2, 3, 4). 4. Remove the BCM (1). INSTALLATION PROCEDURE 1. Install the body control module (BCM) (1). 2. Connect the BCM electrical connectors (2, 3, 4). 3. Install the left instrument panel insulator 4. Connect the battery ground (negative) cable. 5. Perform the new BCM setup. Refer to BCM Programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Powertrain Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 5504 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 5505 Powertrain Control Module: Locations Locations View RH side of the engine compartment, forward of the strut tower, inside air box. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5508 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5509 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5510 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5511 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5512 Powertrain Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5513 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5514 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5515 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5516 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5517 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5518 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5519 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5520 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5521 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5522 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5523 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5524 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5525 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5526 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5527 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5528 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5529 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5530 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5531 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5532 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5533 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5534 Powertrain Control Module: Connector Views Powertrain Control Module Connector C1 End View (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5535 Powertrain Control Module Connector C1 End View (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5536 Powertrain Control Module Connector C2 End View (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5537 Powertrain Control Module Connector C2 End View (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > EEPROM Programming Powertrain Control Module: Service and Repair EEPROM Programming 1. The ignition is ON. 2. If the PCM fails to program, inspect the Techline equipment for the latest software version. 3. Attempt to program the PCM. If the PCM still cannot be programmed properly, replace the PCM. The replacement PCM must be programmed. Functional Check 1. Perform A Powertrain On Board Diagnostic (OBD) System Check. 2. Start the engine and let the engine run for one minute. 3. Use the scan tool in order to scan for the DTCs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > EEPROM Programming > Page 5540 Powertrain Control Module: Service and Repair PCM Replacement/Programming NOTE: In order to prevent possible Electrostatic Discharge damage to the PCM, Do Not touch the connector pins or the soldered components on the circuit board. Service of the PCM should normally consist of either replacement of the PCM or EEPROM programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if it is the correct part. If it is, remove the faulty PCM and install the new service PCM. NOTE: Turn the ignition OFF when installing or removing the PCM connectors and disconnecting or reconnecting the power to the PCM (battery cable, PCM pigtail, PCM fuse, jumper cables, etc.) in order to prevent internal PCM damage. IMPORTANT: When replacing the production PCM with a service PCM, it is important to transfer the broadcast code and production PCM number to the service PCM label. Do not record on PCM cover. This will allow positive identification of PCM parts throughout the service life of the vehicle. THE SERVICE PCM EEPROM WILL NOT BE PROGRAMMED. DTC P0602 indicates the EEPROM is not programmed or has malfunctioned. Removal Procedure CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Disconnect the IAT sensor electrical connector. 3. Remove the 3 bolts from the inner fender brace and remove the brace. 4. Loosen the clamps securing the air intake duct/MAF sensor to the air cleaner housing and throttle body. 5. Carefully remove the air intake duct/MAF sensor from the throttle body and air cleaner housing (1). 6. Remove the 2 screws (2) from the 2 air cleaner housing sections. 7. Remove the air cleaner housing cover assembly. 8. Without disconnecting the PCM connectors, remove the PCM (4) and harness from the PCM housing (3). 9. Disconnect the PCM connectors. Installation Procedure 1. Connect the PCM connectors. 2. Carefully install the PCM (4) and harness into the PCM housing (3). 3. Install the air cleaner housing cover assembly (1). 4. Install the 2 screws to the 2 air cleaner housing sections. 5. Carefully install the air intake duct to the throttle body and air cleaner housing. 6. Tighten the clamp securing the air intake duct to the air cleaner housing. 7. Position the inner fender brace and reinstall the 3 bolts. 8. Connect the Negative Battery Cable. 9. If a replacement PCM is being installed, program the PCM. The replacement PCM will NOT allow Secondary AIR Pump operation until a total of 10 miles have accumulated. 10. If a replacement PCM is being installed, perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations LF of the engine compartment, in the air cleaner duct. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions Mass Air Flow (MAF) Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5547 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5548 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5549 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5550 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5551 Mass Air Flow (MAF) Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5552 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5553 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5554 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5555 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5556 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5557 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5558 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5559 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5560 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5561 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5562 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5563 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5564 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5565 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5566 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5567 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5568 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5569 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5570 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5571 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5572 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5573 Mass Air Flow (MAF) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5574 Mass Air Flow (MAF) Sensor: Electrical Diagrams Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5575 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Page 5576 Mass Air Flow (MAF) Sensor: Description and Operation The Mass Air Flow (MAF) sensor measures the amount of air which passes through it. The PCM uses this information to determine the operating condition of the engine, to control fuel delivery. A large quantity of air indicates acceleration, while a small quantity indicates deceleration or idle. The scan tool reads the MAF value and displays it in grams per second (gm/s). At idle, it should read between 4 gm/s to 6 gm/s on a fully warmed up engine. Values should change rather quickly on acceleration, but values should remain fairly stable at any given RPM. A failure in the MAF sensor or circuit should set DTC P0101 Mass Air Flow (MAF) Sensor Performance, DTC P0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency, or DTC P0103 Mass Air Flow (MAF) Sensor Circuit High Frequency The MAF sensor is attached to the front (air inlet side) of the throttle body and is used to measure the amount of air entering the engine. The PCM uses this information to determine the operating condition of the engine and to control fuel delivery. For further information, refer to Information Sensors/Switches Description. See: Description and Operation/Information Sensors/Switches Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Page 5577 Mass Air Flow (MAF) Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the MAF sensor (1) electrical connector. 4. Remove the air inlet duct from the MAF sensor and the throttle body. 5. Remove the MAF sensor from the air filter housing. INSTALLATION PROCEDURE 1. Install the MAF sensor to the air filter housing. 2. Install the air inlet duct to the MAF sensor and throttle body. 3. Connect the IAT sensor (1) electrical connector. 4. Connect the MAF sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 89 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations RH side of the engine, below the intake plenum. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 5583 Camshaft Position Sensor: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 5584 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5587 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5588 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5589 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5590 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5591 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5592 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5593 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5594 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5595 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5596 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5597 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5598 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5599 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5600 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5601 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5602 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5603 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5604 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5605 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5606 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5607 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5608 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5609 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5610 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5611 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5612 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5613 Camshaft Position Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position (CMP) Sensor and Cam Signal Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor and Cam Signal The camshaft position sensor sends a cam signal to the PCM which uses it as a sync pulse to trigger the injectors in proper sequence. The PCM uses the CAM signal to indicate the position of the #1 piston during its intake stroke. This allows the PCM to calculate true Sequential Fuel Injection (SFI) mode of operation. If the PCM detects an incorrect CAM signal while the engine is running, DTC P0341 Camshaft Position (CMP) Sensor Performance will set. If the CAM signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection mode based on the last fuel injection pulse, and the engine will continue to run. The engine can be restarted and will run in the calculated sequential mode as long as the fault is present with a 1 in 6 chance of injector sequence being correct. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position (CMP) Sensor and Cam Signal > Page 5616 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The camshaft position sensor is located on the timing cover behind the water pump near the camshaft sprocket. As the camshaft sprocket turns, a magnet in it activates the Hall-effect switch in the camshaft position sensor. When the Hall-effect switch is activated, it grounds the signal line to the PCM, pulling the camshaft position sensor signal circuit's applied voltage low. This is interpreted as a CAM signal. The CAM signal is created as piston #1 is on the intake stroke. If the correct CAM signal is not received by the PCM, DTC P0341 will be set. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 5617 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the serpentine drive belt. 3. Loosen the power steering pump to gain access to the CMP. 4. Disconnect the sensor electrical connector. 5. Remove the attaching bolt. 6. Remove the sensor. 7. Inspect the sensor for wear, cracks or leakage if the sensor is not being replaced. INSTALLATION PROCEDURE 1. Lubricate the O-ring with clean engine oil and replace if damaged. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the camshaft position sensor. Tighten Tighten the retaining bolt to 10 N.m (88 lb in). 3. Connect the sensor electrical connector. 4. Install the power steering pump. 5. Reinstall the serpentine drive belt. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor 23 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 5621 Coolant Temperature Sensor/Switch (For Computer): Locations LH side, top of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5624 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5625 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5626 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5627 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5628 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5629 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5630 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5631 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5632 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5633 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5634 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5635 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5636 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5637 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5638 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5639 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5640 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5641 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5642 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5643 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5644 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5645 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5646 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5647 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5648 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5649 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5650 Engine Coolant Temperature (ECT) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 5651 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 5652 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The engine coolant temperature sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance (100,000 ohms at -40°C/-40°F) while high temperature causes low resistance (70 ohms at 130° C/266° F). The PCM supplies a 5.0 volt signal to the engine coolant temperature sensor through a resistor in the PCM and measures the voltage. The voltage will be high when the engine is cold, and low when the engine is hot. By measuring the voltage, the PCM calculates the engine coolant temperature. Engine coolant temperature affects most systems the PCM controls. The scan tool displays engine coolant temperature in degrees. After engine startup, the temperature should rise steadily to about 90°C (194°F) then stabilize when thermostat opens. If the engine has not been run for several hours (overnight), the engine coolant temperature and intake air temperature displays should be close to each other. A hard fault in the engine coolant sensor circuit should set DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage, or DTC P0118 Engine Coolant Temperature (ECT) Sensor Circuit High Voltage, an intermittent fault should set a DTC P1114 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent Low Voltage, or DTC P1115 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent High Voltage. The DTC Diagnostic Aids also contains a chart to test for sensor resistance values relative to temperature. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 5653 The ECT sensor (3) also contains another circuit which is used to operate the engine coolant temperature gauge located in the instrument panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 5654 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Relieve coolant pressure. 3. Disconnect the ECT sensor electrical connector. 4. Using a deep well socket and extension, remove the sensor. INSTALLATION PROCEDURE 1. Coat the engine coolant temperature sensor threads with sealer P/N 9985253 or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the sensor in the engine. Tighten Tighten the sensor to 23 N.m (17 lb ft). 3. Connect the ECT sensor electrical connector. 4. Start the engine. 5. Inspect for leaks. 6. Inspect the coolant level. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt Front Cover 89 in.lb Crankshaft Position Sensor Stud Side of Engine Block 98 in.lb Crankshaft Position Sensor Wiring Bracket Bolt 37 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 5660 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 5661 Locations View Crankshaft Position (24X) Sensor RH side of the engine, at the end of the crankshaft, behind the harmonic balancer. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 5662 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5665 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5666 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5667 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5668 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5669 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5670 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5671 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5672 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5673 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5674 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5675 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5676 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5677 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5678 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5679 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5680 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5681 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5682 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5683 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5684 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5685 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5686 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5687 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5688 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5689 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5690 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5691 Crankshaft Position Sensor (24X) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 7X Crankshaft Position (CKP) Sensor Crankshaft Position Sensor: Description and Operation 7X Crankshaft Position (CKP) Sensor The 7X crankshaft position sensor provides a signal used by the ignition control module. The ignition control module also uses the 7X crankshaft position sensor to generate 3X reference pulses which the PCM uses to calculate RPM and crankshaft position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 7X Crankshaft Position (CKP) Sensor > Page 5694 Crankshaft Position Sensor: Description and Operation 24X Crankshaft Position (CKP) Sensor 24X Crankshaft Position (CKP) Sensor The 24X crankshaft position (CKP) sensor (1) is used to improve idle spark control at engine speeds up to approximately 1600 RPM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure The Crankshaft Position System Variation compensating values are stored in the PCM non-volatile memory after a learn procedure has been performed. If the actual Crankshaft Position System Variation is not within the Crankshaft Position System Variation compensating values stored in the PCM, DTC P0300 may set. Refer to Diagnostic Aids for DTC P0300. The Crankshaft Position System Variation Learn Procedure should be performed if any of the following conditions are true: ^DTC P1336 is set. ^ The PCM has been replaced. ^ The engine has been replaced. ^ The crankshaft has been replaced. ^ The crankshaft harmonic balancer has been replaced. ^ The crankshaft position sensor has been replaced. Important: The scan tool Crankshaft Position System Variation Learn function will be inhibited if engine coolant temperature is less than 70°C (158°F). Allow the engine to warm to at least 70°C (158°F) before attempting the Crankshaft Position System Variation Learn Procedure. The scan tool Crankshaft Position System Variation Learn function will be inhibited if any Powertrain DTCs other than DTC P1336 are set before or during the Crankshaft Position System Variation Learn Procedure. Diagnose and repair any DTCs if set. Refer to applicable DTCs. The Crankshaft Position System Variation Learn function will be inhibited if the PCM detects a malfunction involving the camshaft position signal circuit, the 3X reference circuit, or the 24X reference circuit. If a malfunction has been indicated, refer to the following list to diagnose the system or sensor. ^ DTC P0336 Crankshaft Position (CKP) Sensor Circuit. ^ DTC P0341 Camshaft Position (CMP) Sensor Performance. ^ DTC P1374 Crankshaft Position (CKP) High to Low Resolution Frequency Correlation. The scan tool Crankshaft Position System Variation Learn function will not be enabled until engine coolant temperature reaches 70°C (158°F) Selecting the crankshaft position system variation learn procedure on the scan tool will command the PCM to enable CKP system variation learn fuel cutoff and allow the crankshaft position system variation compensating values to be stored in the PCM. The PCM must detect an engine speed of 5150 RPM (CKP system variation learn fuel cutoff) during the Crankshaft Position System Variation Learn Procedure to store the crankshaft position system variation compensating values and complete the procedure. Important: Block the drive wheels when performing the Crankshaft Position System Variation Learning Procedure in order to prevent personal injury. Set the vehicle parking brake when instructed by the scan tool. Quickly increase the accelerator pedal until wide open throttle is reached and hold. During the learn procedure the PCM will automatically control injector operation, when the RPM has reached a certain RPM the PCM will stop the fuel injectors from pulsing until the learn procedure is finished. When the PCM has learned the crankshaft variation the fuel injectors will return to normal operation and the engine will begin to accelerate again. Release the throttle when the engine reaches the second fuel cut off. Leaving the throttle open during the fuel cut off learn procedure will allow the engine to decel at an even rate. 1. Block the drive wheels. 2. Ensure the hood is closed. 3. Start the engine and allow engine coolant temperature to reach at least 70°C (158°F) 4. Turn OFF the ignition. 5. Select and enable the Crankshaft Position System Variation Learn Procedure with the scan tool. 6. Set the parking brake when instructed by the scan tool. 7. Start the vehicle. 8. Apply and hold the service brake pedal firmly. 9. Ensure the transaxle is in park. 10. Steadily increase the accelerator pedal until the fuel cutoff is reached at 5150 RPM and hold. Release the accelerator pedal after the second fuel cutoff has been reached. 11. The crankshaft position system variation compensating values are learned when the RPM decreases back to idle. If the procedure terminates. 12. Observe DTC status for DTC P1336. 13. If the scan tool indicates that DTC P1336 ran and passed, the Crankshaft Position System Variation Learn Procedure is complete. If the scan tool indicates DTC P1336 failed or not run, determine if other DTCs have set. If DTCs other than P1336 are not set, repeat the Crankshaft Position System Variation Learn Procedure as necessary. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5697 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement (7X) REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Crank steering wheel fully to the left. 3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting. 4. Remove the right tire and wheel. 5. Disconnect the sensor electrical connector. 6. Remove the attaching bolt/screw. 7. Remove the sensor from engine. 8, Inspect for wear, cracks, or leakage if the sensor is not being replaced. INSTALLATION PROCEDURE 1. Lubricate the O-ring with clean engine oil before installation and replace if damaged. 2. Install the sensor to the block. 3. Reinstall the sensor attaching bolt. Tighten Tighten the bolt to 11 N.m (97 lb in). 4. Connect the sensor electrical connector. 5. Install the right tire and wheel. 6. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5698 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement (24X) REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the serpentine drive belt from crankshaft pulley. 3. Raise the vehicle on hoist. Refer to Lifting and Jacking the Vehicle in General Information 4. Remove the crankshaft harmonic balancer. 5. Note the routing of sensor harness before removal. 6. Remove the harness retaining clip with bolt (1). 7. Disconnect the sensor electrical connector. 8, Remove the sensor bolts (4). 9. Remove the sensor. INSTALLATION PROCEDURE 1. Install the 24X crankshaft position sensor with bolts (4) and route harness as noted during removal. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the harness retaining clip with bolt (3). Tighten Tighten the bolts to 10 N.m (88 lb in). 3. Connect the sensor electrical connector. 4. Reinstall the balancer on the crankshaft. 5. Lower vehicle. 6. Reinstall the serpentine drive belt. 7. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Description and Operation EGR Valve Position Sensor: Description and Operation The Exhaust Gas Recirculation (EGR) pintle position sensor is an integral part of the EGR valve assembly. This sensor can not be serviced separately from the EGR valve assembly. EGR Pintle Position Sensor The PCM monitors the EGR valve pintle position input to ensure that the valve responds properly to commands from the PCM and to detect a fault if the pintle position sensor and control circuits are open or shorted. If the PCM detects a pintle position signal voltage outside the normal range of the pintle position sensor, or a signal voltage that is not within a tolerance considered acceptable for proper EGR system operation, the PCM will set DTC P1404 EGR valve stuck open. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Mounted in the fuel tank. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 5705 Fuel Level Sensor: Description and Operation The fuel level sensor consists of the following components: float, the wire float arm, and the ceramic resistor card. The fuel level sensor is mounted on the modular fuel sender assembly and is used as an input to the PCM. The PCM uses this information as a fuel level input for Various diagnostics. In addition the PCM transmits the fuel level over the Class II communication circuit to the IP cluster. This information is used for the IP fuel gauge, and low fuel warning indicator if applicable. Fuel Level Sensor The Fuel Level Sensor(4) is mounted on the Modular Fuel Sender Assembly(s). The PCM uses the fuel level input for various diagnosis including the EVAP System. In addition the PCM transmits the fuel level over the Class II communication circuit to the IP Cluster. The low fuel level message may not appear if other messages are being commanded, such as the rear deck lid, driver or passenger doors ajar. Ensure that all doors and compartment lids are completely closed. For further information regarding the Fuel Level Sensor refer to Fuel Metering Modes of Operation. See: Fuel Delivery and Air Induction/Description and Operation/Fuel Metering/Fuel Metering Modes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 5706 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure. See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair 2. Remove the modular fuel sender assembly. 3. Remove the fuel level sensor (5) from the modular fuel sender. INSTALLATION PROCEDURE 1. Reinstall the fuel level sensor (5) to modular fuel sender. 2. Reinstall the fuel sender assembly. 3. Tighten the fuel filler cap. 4. Reconnect the negative battery cable. 5. Inspect for fuel leaks. 5.1. Turn the ignition ON for 2 seconds 5.2. Turn the ignition OFF for 10 seconds. 5.3. Turn the ignition ON. 5.4. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Fuel Tank Pressure (FTP) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Fuel Tank Pressure Sensor - 1 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor - 1 The Fuel Tank Pressure (FTP) sensor measures the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The sensor mounts at the top of the fuel tank sending unit. The PCM supplies a 5 volt reference voltage and ground to the sensor. The sensor provides a signal voltage between 0.1-4.9 volts to the PCM. When the air pressure in the fuel tank is equal to the outside air pressure, such as when the fuel fill cap is removed, the output voltage of the sensor will measure 1.3-1.7 volts. When the air pressure in the tank is 4.5 inches H20 (1.25 kPa), the sensor output voltage should measure 0.5 ± 0.2 volts (1.25 kPa). The sensor voltage increases to approximately 4.5 volts at 14 inches of H2O (-3.75 kpa). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Fuel Tank Pressure Sensor - 1 > Page 5712 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor - 2 Fuel Tank Pressure Sensor The Fuel Tank Pressure Sensor(6) is mounted on top the Modular Fuel Sender Assembly(S). The PCM uses the fuel tank pressure input for the EVAP System. The PCM supplies a 5 volt reference to the sensor and a sensor return (ground). The PCM monitors the signal circuit from the sensor with a voltage range from 0.1 volts to 4.9 volts. When the pressure inside the fuel tank is totally vented the pressure is equal to atmospheric pressure or approximately 1.3-1.7 volts. When the tank is pressurized the voltage can reach more than 4.5 volts. For further information regarding the Fuel Tank Pressure Sensor refer to Fuel Metering Modes of Operation, and EVAP Control System Operation Description. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Fuel Tank Pressure Sensor - 1 > Page 5713 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor - 3 Fuel Tank Pressure Sensor The Fuel Tank Pressure (FTP) sensor measures the difference between the air pressure, or vacuum, in the fuel tank and the outside air pressure. The sensor mounts at the top of the fuel tank sending unit. The PCM supplies a 5 volt reference voltage and ground to the sensor. The sensor provides a signal voltage between 0.1-4.9 volts to the PCM. When the air pressure in the fuel tank is equal to the outside air pressure, such as when the fuel fill cap is removed, the output voltage of the sensor will measure 1.3-1.7 volts. When the air pressure in the tank is 1.25 kPa (4.5 inches Hg), the sensor output voltage should measure 1.25 kPa (approx 0.5 volts). The sensor voltage increases to approximately 4.5 volts at -3.75 kPa (14 inches of Hg). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 5714 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the spare tire cover, the jack, and the spare tire. 3. Remove the trunk liner. 4. Remove the 7 nuts retaining the fuel sender access panel. 5. Remove the fuel sender access panel. 6. Disconnect the electrical connector from the fuel tank vapor pressure sensor. 7. Remove the fuel tank vapor pressure sensor (7) from modular fuel sender assembly. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 5715 1. Reinstall the new fuel tank vapor pressure sensor (7) to modular fuel sender. 2. Connect the electrical connector to fuel tank vapor pressure sensor 3. Reinstall the fuel sender access panel. 4. Reinstall the 7 nuts retaining the fuel sender access panel. Tighten Tighten the fuel sender access panel nuts to 10 N.m (88 lb in) 5. Reinstall the trunk liner. 6. Reinstall the spare tire, the jack, and the spare tire cover. 7. Reconnect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Intake Air Temperature (IAT) Sensor: Locations Intake Air Temperature (IAT) Sensor is in the air induction tube. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions Intake Air Temperature (IAT) Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5721 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5722 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5723 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5724 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5725 Intake Air Temperature (IAT) Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5726 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5727 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5728 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5729 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5730 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5731 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5732 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5733 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5734 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5735 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5736 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5737 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5738 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5739 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5740 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5741 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5742 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5743 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5744 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5745 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5746 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5747 Intake Air Temperature Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5748 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Page 5749 Intake Air Temperature (IAT) Sensor: Description and Operation The Intake Air Temperature (IAT) sensor is a thermistor which changes value based on the temperature of air entering the engine. Low temperature produces a high resistance (100,000 ohms at -40°C/-40°F), while high temperature causes low resistance (70 ohms at 130°C/266°F). The PCM supplies a 5.0 volt signal to the sensor through a resistor in the PCM and measures the voltage. The voltage will be high when the incoming air is cold, and low when the air is hot. By measuring the voltage, the PCM calculates the incoming air temperature. The IAT sensor signal is used to adjust spark timing according to incoming air density. The scan tool displays temperature of the air entering the engine, which should read close to ambient air temperature when the engine is cold, and rise as the underhood temperature increases. If the engine has not been run for several hours (overnight) the IAT sensor temperature and engine coolant temperature should read close to each other. A failure in the IAT sensor circuit should set DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage or DTC P0113 Intake Air Temperature (IAT) Sensor Circuit High Voltage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Page 5750 Intake Air Temperature (IAT) Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the IAT sensor electrical connector. 3. Carefully grasp the sensor and with a twisting and pulling motion, remove the IAT sensor from air intake duct. INSTALLATION PROCEDURE 1. Install the IAT sensor (snap into place). 2. Connect the IAT sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications knock Sensor 19 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations Knock Sensor: Component Locations Left Front Of Engine Knock Sensor (KS) Bank 1 Lower RR of the engine, below the exhaust manifold. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations > Page 5756 Knock Sensor: Connector Locations Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations > Page 5757 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5760 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5761 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5762 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5763 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5764 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5765 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5766 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5767 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5768 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5769 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5770 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5771 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5772 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5773 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5774 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5775 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5776 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5777 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5778 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5779 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5780 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5781 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5782 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5783 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5784 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5785 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5786 Knock Sensor (KS) 1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5787 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > General Information Knock Sensor: Description and Operation General Information The knock sensor detects abnormal vibration (spark knocking) in the engine. The sensor is located on the engine block near the cylinders. The sensor produces an AC output voltage which increases with the severity of the knock. This signal voltage is input to the PCM. The PCM then adjusts the Ignition Control (IC) timing to reduce spark knock. DTC P0325 Knock Sensor (KS) Circuit DTC P0327 Knock Sensor (KS) Circuit are designed to diagnose the PCM, the knock sensor, and related wiring, so problems encountered with the KS system should set a DTC. Refer to Knock Sensor (KS) System Description description of the knock sensor system. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > General Information > Page 5790 Knock Sensor: Description and Operation Operation The knock sensor detects abnormal vibration (spark knocking) in the engine. The knock sensor is mounted in the engine block near the cylinders and produce an AC signal under all engine operating conditions. The PCM contains integrated Knock Sensor (KS) diagnostic circuitry which uses the input signals from the knock sensors to detect engine detonation. This allows the PCM to retard Ignition Control (IC) spark timing based on the amplitude and frequency of the KS signal being received. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > General Information > Page 5791 Knock Sensor: Description and Operation Purpose Knock Sensor (KS) System Description Purpose Varying octane levels in todays gasoline may cause detonation in some engines. Detonation is caused by an uncontrolled explosion (burn) in the combustion chamber. This uncontrolled explosion could produce a flame front opposite that of the normal flame front produced by the spark plug. The rattling sound normally associated with detonation is the result of two or more opposing pressures (flame fronts) colliding within the combustion chamber. Though light detonation is sometimes considered normal, heavy detonation could result in engine damage. To control spark knock, a Knock Sensor (KS) system is used. This system is designed to retard spark timing when spark knock is detected in the engine. The KS system allows the engine to use maximum spark advance for optimal driveability and fuel economy. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 5792 Knock Sensor: Testing and Inspection The PCM calculates an average voltage the knock sensor signal and takes instantaneous signal voltage readings. The PCM uses the instantaneous signal voltage reading to determine the state of the knock sensor circuitry. If the knock sensor system is operating normally, the PCM should monitor instantaneous KS signal voltage readings varying outside a voltage range above and below the calculated average voltage. The following DTCs are used to diagnose the knock sensor system: ^ If the PCM malfunctions in a manner which will not allow proper diagnosis of the KS circuits, DTC P0325 will set. ^ DTC P0327 is designed to diagnose the knock sensor, and related wiring, so problems encountered with the KS system should set a DTC. However, if no DTC was set but the KS system is suspect because detonation was the customer's complaint, use the tables for P0327 to diagnose the Detonation/Spark Knock Symptom. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 5793 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting. 3. Disconnect the knock sensor wiring harness connector from the knock sensor. 4. Remove the knock sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Do Not apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. NOTE: Refer to Fastener Notice in Service Precautions. Knock Sensor (KS) System Deascription Purpose 1. Install the knock sensor into engine block. Tighten Tighten the knock sensor to 19 N.m (14 lb ft). 2. Connect the knock sensor wiring harness connector to the knock sensor. 3. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications Manifold Absolute Pressure (MAP) Sensor: Specifications Manifold Absolute Pressure (MAP) Sensor Retaining Bolt 3 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 5797 Manifold Absolute Pressure (MAP) Sensor: Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 5798 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions Manifold Absolute Pressure (MAP) Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5801 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5802 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5803 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5804 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5805 Manifold Absolute Pressure (MAP) Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5806 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5807 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5808 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5809 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5810 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5811 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5812 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5813 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5814 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5815 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5816 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5817 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5818 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5819 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5820 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5821 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5822 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5823 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5824 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5825 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5826 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5827 Manifold Air Pressure (MAP) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 5828 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Page 5829 Manifold Absolute Pressure (MAP) Sensor: Description and Operation The Manifold Absolute Pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the PCM varies from below 2.0 volts at idle (high vacuum) to above 4.0 volts with the key ON, and the engine OFF, or at wide open throttle (low vacuum). The MAP sensor is used to determine manifold pressure changes while the linear EGR flow test diagnostic is being run, Refer to DTC P0401 Exhaust Gas Recirculation (EGR) Flow Insufficient, to determine engine vacuum level for other diagnostics and to determine Barometric Pressure (BARO). If the PCM detects a voltage that is lower than the possible range of the MAP sensor, DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage will be set. A signal voltage higher than the possible range of the sensor will set DTC P0108 Manifold Absolute Pressure (MAP) Sensor Circuit High Voltage. An intermittent low or high voltage will set DTC P1107 Manifold Absolute Pressure (MAP) Sensor Circuit Intermittent Low Voltage or DTC P1106 Manifold Absolute Pressure (MAP) Sensor Circuit Intermittent High Voltage respectively. The PCM can also detect a shifted MAP sensor. The PCM compares the MAP sensor signal to a calculated MAP based on throttle position and various engine load factors Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Page 5830 Manifold Absolute Pressure (MAP) Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the MAP sensor from the bracket. 2. Disconnect the MAP inlet vacuum hose. 3. Disconnect the MAP sensor electrical connector. INSTALLATION PROCEDURE 1. Connect the MAP sensor electrical connector. 2. Connect the inlet vacuum hose. 3. Position the MAP sensor to bracket and tighten fasteners. Tighten Tighten the MAP sensor fasteners to 3 N.m (27 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations Oil Level Sensor For ECM: Locations Front center of the engine oil pan. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 5834 Engine Oil Level Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 5838 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Heated Oxygen Sensors 41 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 5844 Locations View Heated Oxygen Sensor 1 (HO2S1) Rear of the engine, in the exhaust manifold. Heated Oxygen Sensor 2 (HO2A2) In the exhaust system, behind the catalytic converter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 5845 Oxygen Sensor: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 5846 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5849 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5850 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5851 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5852 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5853 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5854 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5855 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5856 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5857 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5858 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5859 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5860 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5861 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5862 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5863 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5864 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5865 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5866 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5867 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5868 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5869 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5870 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5871 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5872 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5873 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5874 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5875 Oxygen Sensor: Connector Views Heated Oxygen Sensor (HO2S2) 1 Heated Oxygen Sensor (HO2S2) 2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5876 Oxygen Sensor: Electrical Diagrams Schematic Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Fuel Control Heated Oxygen Sensor (HO2S 1) Oxygen Sensor: Description and Operation Fuel Control Heated Oxygen Sensor (HO2S 1) Fuel Controlled Heated Oxygen Sensor (H02S 1) The fuel control Heated Oxygen Sensor (HO2S 1) is mounted in the exhaust manifold where it can monitor the oxygen content of the exhaust gas stream. The oxygen present in the exhaust gas reacts with the sensor to produce a voltage output. This voltage should constantly fluctuate from approximately 100 mV (high oxygen content lean mixture) to 900 mV (low oxygen content rich mixture). The heated oxygen sensor voltage can be monitored with a scan tool. By monitoring the voltage output of the oxygen sensor, the PCM calculates what fuel mixture command to give to the injectors (lean mixture low HO2S voltage = rich command, rich mixture high HO2S voltage = lean command). The HO2S 1 circuit, if open, should set a DTC P0134 HO2S Circuit Insufficient Activity Sensor 1 and the scan tool will display a constant voltage between 400-500 mV. A constant voltage below 300 mV in the sensor circuit (circuit grounded) should set DTC P0131 HO2S Circuit Low Voltage Sensor 1, while a constant voltage above 800 mV in the circuit should set DTC P0132 HO2S Circuit High Voltage Sensor 1. A fault in the HO2S 1 heater circuit should cause DTC P0135 to set. The PCM can also detect HO2S response problems. If the response time of an HO2S is determined to be too slow, the PCM will store a DTC that indicates degraded HO2S performance. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Fuel Control Heated Oxygen Sensor (HO2S 1) > Page 5879 Oxygen Sensor: Description and Operation Catalyst Monitor Heated Oxygen Sensor (HO2S 2) To control emissions of Hydrocarbons (HC), Carbon Monoxide (CO), and oxides of nitrogen (NOx), a three-way catalytic converter is used. The catalyst within the converter promotes a chemical reaction which oxidizes the HG and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The PCM has the ability to monitor this process using the HO2S 1 and the HO2S 2. The HO2S 1 produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The HO2S 2 produces an output signal which indicates the oxygen storage capacity of the catalyst, this in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the HO2S 1 signal will be far more active than that produced by the HO2S 2. The catalyst monitor sensors operate the same as the fuel control sensors. Although the HO2S 2 main function is catalyst monitoring, it also plays a limited role in fuel control. If the sensor output indicates a voltage either above or below the 450 millivolt bias voltage for an extended period of time, the PCM will make a slight adjustment to fuel trim to ensure that fuel delivery is correct for catalyst monitoring. A problem with the HO2S 2 signal circuit should set DTC P0137 HO2S Circuit Low Voltage Sensor 2, DTC P0138 HO2S Circuit High Voltage Sensor 2, or DTC P0140 HO2S Circuit Insufficient Activity Sensor 2, depending on the specific condition. A fault in the heated oxygen sensor heater element or its ignition feed or ground will result in slower oxygen sensor response. This may cause erroneous Catalyst monitor diagnostic results. A fault in the HO2S 2 heater circuit should cause DTC P0141 HO2S Heater Performance Sensor 2 to set. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement (HO2S1) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement (HO2S1) TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Socket REMOVAL PROCEDURE (HO2S1) The heated oxygen sensor may be difficult to remove when engine temperature is below 48°C (120°F). Excessive force may damage threads in exhaust manifold or exhaust pipe. 1. Turn OFF the ignition. 2. Disconnect the electrical connector. IMPORTANT: A special anti seize compound is used on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine and if for any reason is to be reinstalled, the threads must have anti seize compound applied before reinstallation. 3. Using J 39194-B heated oxygen sensor socket carefully back out the heated oxygen sensor. INSTALLATION PROCEDURE (HO2S1) 1. Coat the threads of heated oxygen sensor/catalyst monitor with anti seize compound P/N 5613695, or equivalent if necessary. 2. Install the heated oxygen sensor. Tighten Tighten the HO2S 1 (Pre-catalytic converter) to 41 N.m (30 lb ft). 3. Connect the HO2S1 sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement (HO2S1) > Page 5882 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement (HO2S2) TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Socket REMOVAL PROCEDURE (HO2S2) The heated oxygen sensor may be difficult to remove when engine temperature is below 48°C (120°F). Excessive force may damage threads in exhaust manifold or exhaust pipe. 1. Turn OFF the ignition. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting. 3. Disconnect the sensor electrical connector. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine and if for any reason is to be reinstalled, the threads must have anti seize compound applied before reinstallation. 4. Using J 39194-B heated oxygen sensor socket carefully back out the heated oxygen sensor. INSTALLATION PROCEDURE (HO2S2) 1. Coat the threads of heated oxygen sensor/catalyst monitor with anti seize compound PIN 5613695, or equivalent if necessary. NOTE: Refer to Fastener Notice in Service Precautions. 2. Using J 39194-B heated oxygen sensor socket install the heated oxygen sensor. Tighten Tighten the HO2S2 to 41 N.m (30 lb ft). 3. Connect the HO2S2 sensor electrical connector. 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screws 2 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 5886 Throttle Position Sensor: Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 5887 Left Front Of Engine Top of the engine, on the throttle body assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5890 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5891 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5892 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5893 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5894 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5895 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5896 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5897 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5898 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5899 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5900 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5901 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5902 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5903 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5904 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5905 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5906 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5907 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5908 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5909 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5910 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5911 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5912 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5913 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5914 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5915 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5916 Throttle Position Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 5917 Throttle Position Sensor: Description and Operation The Throttle Position (TP) sensor is a potentiometer connected to the throttle shaft on the throttle body. By monitoring the voltage on the signal line, the PCM calculates throttle position. As the throttle valve angle is changed (accelerator pedal moved), the TP sensor signal also changes. At a closed throttle position, the output of the TP sensor is low. As the throttle valve opens, the output increases so that at Wide Open Throttle (WOT), the output voltage should be above 4.0 volts. The PCM calculates fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor may cause intermittent bursts of fuel from an injector and unstable idle because the PCM thinks the throttle is moving. A hard failure in the TP sensor 5.0 volt reference or signal circuits should set either a DTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage. A hard failure with the TP Sensor ground circuit may set DTCs DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage, DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage, DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage, or DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage. Once a DTC is set, the PCM will use an artificial default value based on engine RPM, engine load and mass air flow for throttle position and some vehicle performance will return. A high idle may result when either DTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage, or DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage is set. The PCM can detect intermittent TP sensor faults. DTC P1121 Throttle Position (TP) Sensor Circuit Intermittent High Voltage, or DTC P 1122 Throttle Position (TP) Sensor Circuit Intermittent Low Voltage will set it an intermittent high or low circuit failure is being detected. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 5918 The PCM can also detect a shifted TP sensor (2). The PCM monitors throttle position and compares the actual TP sensor reading to a predicted TP value calculated from engine speed. If the PCM detects an out of range condition, DTC P0121 Throttle Position (TP) Sensor Performance will be set. The non-adjustable TP sensor is mounted on the side of the throttle body opposite the throttle lever. It senses the throttle valve angle and relays that information to the PCM. Knowledge of the throttle angle is needed by the PCM to generate the required injector control signals (pulse). For further information, Refer to Information Sensors/Switches Description. See: Description and Operation/Information Sensors/Switches Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 5919 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the TP sensor electrical connector. 3. Remove the 2 TP sensor attaching screws. 4. Remove the TP sensor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 5920 5. Remove the TP sensor O-ring. INSTALLATION PROCEDURE 1. Install the TP sensor O-ring. 2. With the throttle valve in the normal closed idle position, install the TP sensor on the throttle body assembly. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 5921 3. Reinstall the 2 TP sensor attaching screws, using a thread-locking compound on the screws. Loctite (R) 262, GM P/N 1052624, or equivalent should be used. Tighten Tighten the TP sensor attaching screws to 2.0 N.m (18 lb in). 4. Connect the TP sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Inside the automatic transaxle Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5925 Park Neutral Position (PNP) Switch C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Speed Sensor to Case 106 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 5929 Vehicle Speed Sensor: Locations Locations View RR of the engine, on the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5932 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5933 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5934 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5935 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5936 Vehicle Speed Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5937 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5938 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5939 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5940 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5941 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5942 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5943 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5944 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5945 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5946 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5947 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5948 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5949 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5950 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5951 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5952 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5953 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5954 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5955 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5956 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5957 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5958 Vehicle Speed Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 5959 Vehicle Speed Sensor: Service and Repair Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment 3. Remove the vehicle speed sensor wiring harness connector. 4. Remove the vehicle speed sensor bolt (9). 5. Remove the vehicle speed sensor (10) from the extension case. 6. Remove the O-ring (11) from the vehicle speed sensor(10). Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 5960 1. Install the O-ring (111) to the vehicle speed sensor (10). 2. Install the vehicle speed sensor (10) to the extension case. Notice: Refer to Fastener Notice in Service Precautions 3. Install the vehicle speed sensor bolt (9). - Tighten the vehicle speed sensor bolt (9) to 12 Nm (106 inch lbs.). 4. Install the vehicle speed sensor wiring harness connector. 5. Install the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment 6. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screws 2 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 5964 Throttle Position Sensor: Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 5965 Left Front Of Engine Top of the engine, on the throttle body assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5968 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5969 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5970 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5971 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5972 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5973 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5974 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5975 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5976 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5977 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5978 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5979 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5980 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5981 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5982 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5983 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5984 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5985 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5986 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5987 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5988 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5989 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5990 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5991 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5992 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5993 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5994 Throttle Position Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 5995 Throttle Position Sensor: Description and Operation The Throttle Position (TP) sensor is a potentiometer connected to the throttle shaft on the throttle body. By monitoring the voltage on the signal line, the PCM calculates throttle position. As the throttle valve angle is changed (accelerator pedal moved), the TP sensor signal also changes. At a closed throttle position, the output of the TP sensor is low. As the throttle valve opens, the output increases so that at Wide Open Throttle (WOT), the output voltage should be above 4.0 volts. The PCM calculates fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor may cause intermittent bursts of fuel from an injector and unstable idle because the PCM thinks the throttle is moving. A hard failure in the TP sensor 5.0 volt reference or signal circuits should set either a DTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage. A hard failure with the TP Sensor ground circuit may set DTCs DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage, DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage, DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage, or DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage. Once a DTC is set, the PCM will use an artificial default value based on engine RPM, engine load and mass air flow for throttle position and some vehicle performance will return. A high idle may result when either DTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage, or DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage is set. The PCM can detect intermittent TP sensor faults. DTC P1121 Throttle Position (TP) Sensor Circuit Intermittent High Voltage, or DTC P 1122 Throttle Position (TP) Sensor Circuit Intermittent Low Voltage will set it an intermittent high or low circuit failure is being detected. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 5996 The PCM can also detect a shifted TP sensor (2). The PCM monitors throttle position and compares the actual TP sensor reading to a predicted TP value calculated from engine speed. If the PCM detects an out of range condition, DTC P0121 Throttle Position (TP) Sensor Performance will be set. The non-adjustable TP sensor is mounted on the side of the throttle body opposite the throttle lever. It senses the throttle valve angle and relays that information to the PCM. Knowledge of the throttle angle is needed by the PCM to generate the required injector control signals (pulse). For further information, Refer to Information Sensors/Switches Description. See: Description and Operation/Information Sensors/Switches Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 5997 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the TP sensor electrical connector. 3. Remove the 2 TP sensor attaching screws. 4. Remove the TP sensor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 5998 5. Remove the TP sensor O-ring. INSTALLATION PROCEDURE 1. Install the TP sensor O-ring. 2. With the throttle valve in the normal closed idle position, install the TP sensor on the throttle body assembly. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 5999 3. Reinstall the 2 TP sensor attaching screws, using a thread-locking compound on the screws. Loctite (R) 262, GM P/N 1052624, or equivalent should be used. Tighten Tighten the TP sensor attaching screws to 2.0 N.m (18 lb in). 4. Connect the TP sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Inside the automatic transaxle Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 6003 Park Neutral Position (PNP) Switch C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Speed Sensor to Case 106 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 6007 Vehicle Speed Sensor: Locations Locations View RR of the engine, on the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6010 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6011 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6012 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6013 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6014 Vehicle Speed Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6015 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6016 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6017 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6018 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6019 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6020 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6021 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6022 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6023 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6024 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6025 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6026 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6027 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6028 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6029 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6030 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6031 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6032 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6033 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6034 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6035 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6036 Vehicle Speed Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 6037 Vehicle Speed Sensor: Service and Repair Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment 3. Remove the vehicle speed sensor wiring harness connector. 4. Remove the vehicle speed sensor bolt (9). 5. Remove the vehicle speed sensor (10) from the extension case. 6. Remove the O-ring (11) from the vehicle speed sensor(10). Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 6038 1. Install the O-ring (111) to the vehicle speed sensor (10). 2. Install the vehicle speed sensor (10) to the extension case. Notice: Refer to Fastener Notice in Service Precautions 3. Install the vehicle speed sensor bolt (9). - Tighten the vehicle speed sensor bolt (9) to 12 Nm (106 inch lbs.). 4. Install the vehicle speed sensor wiring harness connector. 5. Install the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment 6. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Specifications Air Injection Check Valve: Specifications Secondary AIR Injection Check Valve Bracket Nut 10 Nm Secondary AIR Injection Check Valve Mounting Bolt 10 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Service and Repair > Bank 1 Air Injection Check Valve: Service and Repair Bank 1 REMOVAL PROCEDURE 1. Remove AIR Vacuum hose. CAUTION: Allow the engine to cool before servicing the secondary air injection AIR system in order to reduce the chance of severe burns. 2. Remove the AIR Check Valve pipe, clamps, and bolt. 3. Remove the AIR Check Valve nuts. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Service and Repair > Bank 1 > Page 6046 4. Remove the AIR Check Valve front bracket and bolt. 5. Remove the AIR Check Valve pipe adapters. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the AIR Check Valve pipe adapters. Tighten Tighten the AIR Check Valve pipe adapters to 30 N.m (22 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Service and Repair > Bank 1 > Page 6047 2. Install the AIR Check Valve front bracket, bolt and nut. Tighten Tighten the AIR Check Valve front bracket bolt and nut to 25 N.m (18 lb ft). 3. Install the AIR Check Valve. Tighten Tighten the AIR Check Valve front to 20 N.m (15 lb ft). 4. Install the AIR Check Valve nut. Tighten Tighten the AIR Check Valve nut to 10 N.m (89 lb in). 5. Install the AIR Check Valve pipe, clamps, and bolt. Tighten Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Service and Repair > Bank 1 > Page 6048 Tighten the AIR Check Valve pipe bolt to 10 N.m (89 lb in). 6. Install the AIR Vacuum hose. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Service and Repair > Bank 1 > Page 6049 Air Injection Check Valve: Service and Repair Bank 2 REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the AIR vacuum hose. CAUTION: Allow the engine to cool before servicing the secondary air injection AIR system in order to reduce the chance of severe burns. 3. Remove the AIR Check Valve pipe, clamps, and bolt. 4. Remove the AIR Vacuum Bleed Valve Solenoid and bolt. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Service and Repair > Bank 1 > Page 6050 5. Remove the AIR Check Valve nuts. 6. Remove the AIR Check Valve rear bracket and nuts. 7. Remove the AIR Check Valve pipe adapters. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the AIR Check Valve pipe adapters. Tighten Tighten the AIR Check Valve pipe adapters to 30 N.m (22 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Service and Repair > Bank 1 > Page 6051 2. Install the AIR Check Valve rear bracket and nuts. Tighten Tighten the AIR Check Valve rear bracket nuts to 25 N.m (18 lb ft). 3. Install the AIR Check Valve. Tighten Tighten the AIR Check Valve to 20 N.m (15 lb ft). 4. Install the AIR Check Valve nut. Tighten Tighten the AIR Check Valve nut to 10 N.m (89 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Service and Repair > Bank 1 > Page 6052 5. Install the AIR Vacuum Bleed Valve Solenoid and bolt. Tighten Tighten the AIR Vacuum Bleed Valve Solenoid bolt to 10 N.m (89 lb in). 6. Install the AIR Check Valve pipe, clamps, and bolt. Tighten Tighten the AIR Check Valve pipe bolt to 10 N.m (89 lb in). 7. Install the AIR Vacuum hose. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Hose/Tube > Component Information > Specifications Air Injection Hose/Tube: Specifications Secondary AIR Injection Pipe Nut 10 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Specifications Air Injection Pump: Specifications Secondary AIR Injection Pump Bracket Bolt 50 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Specifications > Page 6059 Secondary Air Injection Reaction (A.I.R.) Pump Motor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Specifications > Page 6060 Air Injection Pump: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Raise the vehicle. Refer to in Lifting and Jacking the Vehicle Vehicle Lifting. 3. Remove the left wheel assembly. 4. Remove the left front fender liner. 5. Loosen the AIR exhaust pipe hose pinch clamp. 6. Disconnect the AIR exhaust hose from the AIR pump. 7. Disconnect the AIR pump electrical connector. 8, Remove the nuts securing AIR pump bracket to the frame. 9. Remove the AIR pump and bracket as an assembly. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Secure the AIR pump and bracket to the frame mount with the nuts. Tighten Tighten the nuts securing the AIR pump mounting bracket to 50 N.m (37 lb ft). 2. Connect the AIR pump electrical connector. 3. Lightly lubricate inner edge of AIR exhaust hose. 4. Attach the AIR exhaust hose to the AIR pump outlet port. 5. Place the AIR exhaust hose pinch clamp around the AIR pump outlet port and exhaust hose connection. 6. Install the left front fender liner. 7. Install the left wheel assembly. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump Relay > Component Information > Locations Underhood Fuse Block (Upper) - RH Engine Compartment Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump Relay > Component Information > Locations > Page 6064 Air Injection Pump Relay: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the underhood electrical center cover. 3. Remove the secondary air pump relay. INSTALLATION PROCEDURE 1. Install the secondary air pump relay. 2. Install the underhood electrical center cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Vacuum Bleed Valve > Component Information > Service and Repair Air Injection Vacuum Bleed Valve: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the vacuum hoses from the vacuum bleed valve. 3. Disconnect the electrical connector from the vacuum bleed valve. 4. Remove the nut that attaches the vacuum bleed valve to the mounting stud. 5. Remove the vacuum bleed valve. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the nut securing the vacuum bleed valve to the mounting stud. Tighten Tighten the mounting nut to 1O N.m (88 lb in). 2. Connect the electrical connector to the vacuum bleed valve. 3. Connect the vacuum hoses to the vacuum bleed valve. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Pulsair Valve, Secondary Air Injection > Component Information > Locations Pulsair Valve: Locations Rear of the engine, in the exhaust manifold. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair Catalytic Converter: Service and Repair Removal Procedure The three way catalytic converter is serviced by replacing the entire assembly. Always replace the gasket at the front flange when servicing the three way catalytic converter. Never reinstall the original gasket. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the heated oxygen sensor electrical connector. 3. Remove the exhaust manifold pipe stud nuts. 4. Remove the catalytic converter bolts. 5. Remove the three way catalytic converter. 6. Remove the heated oxygen sensor. Refer to Heated Oxygen Sensor (H02S) Replacement (H02SI) or Heated Oxygen Sensor (HO2S) Replacement (H02S2) in Computers and Controls. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Page 6074 1. Install the heated oxygen sensor. Refer to Heated Oxygen Sensor (HO25) Replacement (H02S1) or Heated Oxygen Sensor (HO2S) Replacement (H02S2) in Computers and Controls. 2. Install a new exhaust manifold pipe gasket. Notice: Refer to Catalytic Converter Movement Notice in Service Precautions. 3. Install and support the three way catalytic converter. 4. Install the catalytic converter bolts. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Page 6075 5. Install the exhaust manifold pipe stud nuts. - Tighten the exhaust manifold pipe stud nuts to 32 Nm (24 ft. lbs.). - Tighten the catalytic converter bolts to 45 Nm (33 ft. lbs.). 6. Connect the heated oxygen sensor electrical connector. 7. Inspect for leaks and underbody contact. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications Canister Purge Control Valve: Specifications EVAP Canister Purge Valve Bracket 10 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 6080 Canister Purge Control Valve: Service and Repair EVAP Purge Valve REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Note the position of the EVAP hoses for installation. 3. Disconnect the electrical connector and hoses from the EVAP canister purge valve. 4. Remove the bolt from the valve mounting bracket. 5. Remove the EVAP purge valve. INSTALLATION PROCEDURE 1. Position the EVAP canister purge valve on the manifold. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolt and secure the EVAP canister purge valve. Tighten Tighten the purge valve retaining bolt to 10 N.m (88 lb in). 3. Connect the electrical connector and hoses to the valve. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Canister Purge Solenoid: Locations Top rear of the engine, on the intake manifold below the ignition control module. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 6084 EVAP Emission Canister Purge Valve Solenoid Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Specifications Canister Vent Valve: Specifications EVAP Vent Valve Bracket 6 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Component Locations Canister Vent Valve: Component Locations Evaporative Emissions (EVAP) Canister Vent Solenoid Valve Behind the LH rear fascia splash shield in the wheel well. Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Component Locations > Page 6091 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 6092 Evaporative Emission Canister Vent Valve Solenoid Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 6093 Canister Vent Valve: Service and Repair EVAP Vent Valve REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Raise the vehicle. Refer Lifting and Jacking the Vehicle to in Vehicle Lifting. 3. Remove the LT. inner rear fender. 4. Disconnect the EVAP vent valve electrical connector. 5. Disconnect the vent hose from the EVAP vent valve. 6. Remove the EVAP vent valve from the bracket. INSTALLATION PROCEDURE 1. Install the EVAP vent valve onto the bracket. 2. Connect the vent hose to the EVAP vent valve. 3. Connect the EVAP vent valve electrical connector. 4. Install the LT. inner rear fender. 5. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair EGR Tube: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the bolt retaining the pipe assembly from the EGR valve and carefully pull the pipe assembly back. 3. Remove the gasket. 4. Unscrew the EGR pipe assembly nut from the exhaust manifold. 5. Remove the EGR pipe. INSTALLATION PROCEDURE 1. Install the EGR valve pipe to the exhaust manifold. 2. Install a new gasket. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the EGR pipe bolt to the EGR valve. Tighten Tighten the nuts to 30 N.m (22 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications EGR Valve: Specifications Exhaust Gas Recirculation Valve to Throttle Body Adapter Bolts 30 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 6104 EGR Valve: Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 6105 Left Front Of Engine Upper LH side of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 6106 Exhaust Gas Recirculation Valve Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 6107 EGR Valve: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the EGR valve electrical connector. 3. Remove the bolt retaining the pipe assembly from the EGR valve and carefully pull the pipe assembly back. 4. Remove the EGR valve retaining bolts. 5. Remove EGR valve assembly. 6. Remove the gasket. INSTALLATION PROCEDURE 1. Install the EGR valve with a new gasket to the intake manifold. NOTE: Refer to Fastener Notice in Service Precautions. 2. Reinstall the bolts through the EGR valve into the intake manifold. Tighten Tighten the EGR bolts to 30 N.m (22 lb ft). 3. Connect the exhaust pipe assembly to the EGR valve. 4. Reinstall the exhaust pipe bolt. Tighten Tighten the nuts to 30 N.m (22 lb ft). 5. Connect the EGR valve electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Description and Operation EGR Valve Position Sensor: Description and Operation The Exhaust Gas Recirculation (EGR) pintle position sensor is an integral part of the EGR valve assembly. This sensor can not be serviced separately from the EGR valve assembly. EGR Pintle Position Sensor The PCM monitors the EGR valve pintle position input to ensure that the valve responds properly to commands from the PCM and to detect a fault if the pintle position sensor and control circuits are open or shorted. If the PCM detects a pintle position signal voltage outside the normal range of the pintle position sensor, or a signal voltage that is not within a tolerance considered acceptable for proper EGR system operation, the PCM will set DTC P1404 EGR valve stuck open. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Fillpipe Restrictor > Component Information > Specifications Fillpipe Restrictor: Specifications Fuel Tank Filler Pipe Hose Clamp 2.5 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Fillpipe Restrictor > Component Information > Description and Operation > Fuel Tank Filler Pipe Fillpipe Restrictor: Description and Operation Fuel Tank Filler Pipe The fuel tank filler pipe carries dispensed fuel from the fuel nozzle to the fuel tank. In order to prevent refueling with leaded fuel, the fuel tank filler pipe (2) has a built-in restrictor and deflector. The fuel tank filler pipe is connected to the fuel tank filler extension (1) by clamps. Inside the fuel tank filler pipe is a check-valve that prevents fuel from splashing back out of the fuel lank filler pipe during refueling. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Fillpipe Restrictor > Component Information > Description and Operation > Fuel Tank Filler Pipe > Page 6116 Fillpipe Restrictor: Description and Operation Fuel Tank Filler Pipe Cap NOTE: Use a fuel tank filler pipe cap with the same features when a replacement is necessary. Failure to use the correct fuel tank filler pipe cap can result in a serious malfunction of the fuel system. Fuel Tank Filler Pipe Cap The fuel tank filler pipe is equipped with a quarter-turn type fuel tank filler pipe cap. In order to install the fuel tank filler pipe cap, turn the fuel tank filler pipe cap clockwise until a clicking noises is heard. A built-in device indicates that the fuel tank filler pipe cap is fully seated. A fuel filler cap that is not fully seated, may cause a malfunction in the emission system. The fuel fill cap is also part of the (ORVR) EVAP system and has a tether connected to the fuel fill door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Positive Crankcase Ventilation Valve: Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 6121 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Locations Underhood Fuse Block (Upper) - RH Engine Compartment Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Locations > Page 6126 Air Injection Pump Relay: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the underhood electrical center cover. 3. Remove the secondary air pump relay. INSTALLATION PROCEDURE 1. Install the secondary air pump relay. 2. Install the underhood electrical center cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Description and Operation EGR Valve Position Sensor: Description and Operation The Exhaust Gas Recirculation (EGR) pintle position sensor is an integral part of the EGR valve assembly. This sensor can not be serviced separately from the EGR valve assembly. EGR Pintle Position Sensor The PCM monitors the EGR valve pintle position input to ensure that the valve responds properly to commands from the PCM and to detect a fault if the pintle position sensor and control circuits are open or shorted. If the PCM detects a pintle position signal voltage outside the normal range of the pintle position sensor, or a signal voltage that is not within a tolerance considered acceptable for proper EGR system operation, the PCM will set DTC P1404 EGR valve stuck open. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure - Correct Operating Range Fuel Pressure: Technical Service Bulletins Fuel Pressure - Correct Operating Range File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-018 Date: May, 1999 INFORMATION Subject: Correct Fuel Pressure Operating Range Models: 2000 Buick Century 2000 Chevrolet Impala, Lumina, Malibu, Monte Carlo, Venture 2000 Oldsmobile Alero, Silhouette 2000 Pontiac Grand Am, Grand Prix, Montana with 3.1 L or 3.4 L V6 Engine (VINs J, E - RPOs LG8, LA1) All 2000 model year 3.1 L and 3.4 L engines have a revised fuel pressure regulator and Multec II fuel injectors. The fuel system operating pressure is 358-405 kPa (52-59 psi) on these applications. Important: ^ This regulator is NOT interchangeable with past model applications. When replacement is necessary for the above listed applications, use only regulator P/N 17113622. ^ Installing regulators other than the above listed part number in these applications may result in a change in engine performance and/or driveability concerns. Refer to the Engine Controls subsection of the Service Manual for complete diagnostic and repair information on fuel system related concerns. Parts Information Part Number Description 17113622 Fuel Pressure Regulator Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > Page 6136 Fuel Pressure: Specifications Fuel Pressure Fuel Pressure Fuel Pressure 52-59 psi Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis Fuel Pressure: Testing and Inspection Fuel System Diagnosis Diagnostic Chart (Part 1 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 6139 Diagnostic Chart (Part 2 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 6140 Diagnostic Chart (Part 3 Of 3) SYSTEM DESCRIPTION Proper fuel pressure is necessary to maintain efficient engine operation and emission levels, if fuel pressure is not within specifications vehicle driveablity may be affected or emission levels elevated. The fuel system contains the following components: ^ Fuel strainer ^ Modular fuel sender assembly ^ Fuel filter ^ Fuel feed pipes and hoses ^ Fuel pressure regulator ^ Fuel rail ^ Fuel injectors ^ Fuel return pipes and hoses TEST DESCRIPTION The numbers below refer to the step numbers on the diagnostic table. 2. Tests the fuel systems ability to achieve a specific fuel pressure range. It may be necessary to cycle the fuel pump several times to achieve the pressure range. 6. A fuel system that drops more than 5 psi in 10 minutes has a leak in one or more areas. 8. Tests the fuel systems ability to maintain a specific fuel pressure. It may be necessary to cycle the fuel pump several times to achieve the pressure range. 9. Fuel pressure that drops-off during acceleration, cruise, or hard cornering may cause a lean condition. A lean condition can cause a loss of power, surging, or misfire and may be diagnosed using a scan tool. If an extremely lean condition occurs, the oxygen sensors may drop below 500 mV and the fuel injector pulse width will increase. 13. When the engine is at idle, the manifold pressure is low, high vacuum. This low pressure, high vacuum, is applied to the fuel pressure regulator diaphragm, the result is lower fuel pressure. The fuel pressure at idle will vary slightly as the pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in Step 2 with the engine OFF. 14. This test determines if the high fuel pressure is due to a restricted fuel return pipe or fuel pressure regulator. A rich condition may cause a DTC P0132 or DTC P0172 to set. Driveability conditions associated with rich conditions can include hard starting, followed by black smoke, and a Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 6141 strong sulfur smell in the exhaust. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 6142 Fuel Pressure: Testing and Inspection Fuel System Pressure Test Diagnostic Chart (Part 1 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 6143 Diagnostic Chart (Part 2 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 6144 Diagnostic Chart (Part 3 Of 3) SYSTEM DESCRIPTION Proper fuel pressure is necessary to maintain efficient engine operation and emission levels, if fuel pressure is not within specifications vehicle driveablity may be affected or emission levels elevated. The fuel system contains the following components: ^ Fuel strainer ^ Modular fuel sender assembly ^ Fuel filter ^ Fuel feed pipes and hoses ^ Fuel pressure regulator ^ Fuel rail ^ Fuel injectors ^ Fuel return pipes and hoses TEST DESCRIPTION The numbers below refer to the step numbers on the diagnostic table. 2. Tests the fuel systems ability to achieve a specific fuel pressure range. It may be necessary to cycle the fuel pump several times to achieve the pressure range. 6. A fuel system that drops more than 5 psi in 10 minutes has a leak in one or more areas. 8. Tests the fuel systems ability to maintain a specific fuel pressure. It may be necessary to cycle the fuel pump several times to achieve the pressure range. 9. Fuel pressure that drops-off during acceleration, cruise, or hard cornering may cause a lean condition. A lean condition can cause a loss of power, surging, or misfire and may be diagnosed using a scan tool. If an extremely lean condition occurs, the oxygen sensors may drop below 500 mV and the fuel injector pulse width will increase. 13. When the engine is at idle, the manifold pressure is low, high vacuum. This low pressure, high vacuum, is applied to the fuel pressure regulator diaphragm, the result is lower fuel pressure. The fuel pressure at idle will vary slightly as the pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in Step 2 with the engine OFF. 14. This test determines if the high fuel pressure is due to a restricted fuel return pipe or fuel pressure regulator. A rich condition may cause a DTC P0132 or DTC P0172 to set. Driveability conditions associated with rich conditions can include hard starting, followed by black smoke, and a Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 6145 strong sulfur smell in the exhaust. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair RELIEF PROCEDURE Tools Required ^ J34730-1A Fuel Pressure Gauge ^ J34730-262 Fuel Pressure Gauge Fitting CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery terminal. IMPORTANT: Mount the fuel pressure gauge fitting below the belt to avoid contact with the belt. 2. Install the J 34730-262 fuel pressure gauge fitting adaptor to the fuel pressure connection. 3. Connect fuel pressure gauge J 34730-1A to the fuel gauge pressure fitting. Wrap a shop towel around the fuel pressure connection while connecting the fuel pressure gauge in order to avoid spillage. 4. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the fuel pressure gauge into an approved container. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 6152 Idle Speed: Adjustments The Powertrain Control Module (PCM) controls engine idle speed by adjusting the position of the Idle Air Control (IAC) motor pintle. The IAC is a bi-directional motor driven by two coils. The PCM pulses current to the IAC coils in steps, counts, to extend the IAC pintle into a passage in the throttle body to decrease air flow. The PCM reverses the current pulses to retract the pintle, increasing air flow. This method allows highly accurate control of idle speed and quick response to changes in engine load. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Accelerator Pedal: Specifications Accelerator Pedal Retaining Bolt 20 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 6156 Accelerator Pedal: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the left instrument panel sound insulator. 3. Disconnect the accelerator cable (5) from accelerator pedal (1). 4. Remove the bolts (2) and studs (3) holding the accelerator pedal to the bulk head (4). 5. Remove the accelerator pedal. INSTALLATION PROCEDURE 1. Install the accelerator pedal (1) to bulkhead (4). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the accelerator pedal bolt (3) and stud (2). Tighten Tighten the accelerator pedal assembly bolts and studs to 20 N.m (15 lb ft) 3. Connect the accelerator cable (5) to accelerator pedal (1). 4. Inspect the accelerator pedal^ Inspect for complete throttle opening and closing positions by operating the accelerator pedal. The throttle should operate freely without binding between full closed and wide open throttle. ^ Inspect for poor carpet fit under the accelerator pedal. 5. Reinstall the left instrument panel sound insulator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 6166 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 6172 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 6173 Air Filter Element: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the IAT sensor electrical connector. 3. Disconnect the breather tube from the air intake duct. 4. Disconnect the MAF sensor electrical connector. 5. Loosen the air intake duct/MAF sensor hose clamps. 6. Carefully remove the air inlet hose from the throttle body and air cleaner cover. 7. Remove the 2 housing cover retaining clamps. 8, Remove the air cleaner cover (5) and carefully remove the air filter element (6). 9. Inspect the housing cover (5), seal assembly, and air ducting (2) for damage. INSTALLATION PROCEDURE 1. Carefully install the air filter element (6) into the air cleaner assembly (1). 2. Install the housing cover (5) and install the housing cover retaining screws (2). 3. Carefully install the air inlet hose to the throttle body and air cleaner cover. 4. Tighten the air inlet hose clamp. 5. Install the air intake duct/MAF sensor assembly. 6. Tighten the air intake duct/MAF sensor hose clamps. 7. Connect the breather tube to the air intake duct. 8, Connect the MAF sensor electrical connector. 9. Connect the IAT sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations LF of the engine compartment, in the air cleaner duct. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions Mass Air Flow (MAF) Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6179 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6180 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6181 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6182 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6183 Mass Air Flow (MAF) Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6184 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6185 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6186 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6187 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6188 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6189 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6190 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6191 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6192 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6193 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6194 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6195 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6196 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6197 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6198 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6199 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6200 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6201 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6202 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6203 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6204 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6205 Mass Air Flow (MAF) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6206 Mass Air Flow (MAF) Sensor: Electrical Diagrams Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6207 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Page 6208 Mass Air Flow (MAF) Sensor: Description and Operation The Mass Air Flow (MAF) sensor measures the amount of air which passes through it. The PCM uses this information to determine the operating condition of the engine, to control fuel delivery. A large quantity of air indicates acceleration, while a small quantity indicates deceleration or idle. The scan tool reads the MAF value and displays it in grams per second (gm/s). At idle, it should read between 4 gm/s to 6 gm/s on a fully warmed up engine. Values should change rather quickly on acceleration, but values should remain fairly stable at any given RPM. A failure in the MAF sensor or circuit should set DTC P0101 Mass Air Flow (MAF) Sensor Performance, DTC P0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency, or DTC P0103 Mass Air Flow (MAF) Sensor Circuit High Frequency The MAF sensor is attached to the front (air inlet side) of the throttle body and is used to measure the amount of air entering the engine. The PCM uses this information to determine the operating condition of the engine and to control fuel delivery. For further information, refer to Information Sensors/Switches Description. See: Computers and Control Systems/Description and Operation/Information Sensors/Switches Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Page 6209 Mass Air Flow (MAF) Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the MAF sensor (1) electrical connector. 4. Remove the air inlet duct from the MAF sensor and the throttle body. 5. Remove the MAF sensor from the air filter housing. INSTALLATION PROCEDURE 1. Install the MAF sensor to the air filter housing. 2. Install the air inlet duct to the MAF sensor and throttle body. 3. Connect the IAT sensor (1) electrical connector. 4. Connect the MAF sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fillpipe Restrictor > Component Information > Specifications Fillpipe Restrictor: Specifications Fuel Tank Filler Pipe Hose Clamp 2.5 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fillpipe Restrictor > Component Information > Description and Operation > Fuel Tank Filler Pipe Fillpipe Restrictor: Description and Operation Fuel Tank Filler Pipe The fuel tank filler pipe carries dispensed fuel from the fuel nozzle to the fuel tank. In order to prevent refueling with leaded fuel, the fuel tank filler pipe (2) has a built-in restrictor and deflector. The fuel tank filler pipe is connected to the fuel tank filler extension (1) by clamps. Inside the fuel tank filler pipe is a check-valve that prevents fuel from splashing back out of the fuel lank filler pipe during refueling. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fillpipe Restrictor > Component Information > Description and Operation > Fuel Tank Filler Pipe > Page 6215 Fillpipe Restrictor: Description and Operation Fuel Tank Filler Pipe Cap NOTE: Use a fuel tank filler pipe cap with the same features when a replacement is necessary. Failure to use the correct fuel tank filler pipe cap can result in a serious malfunction of the fuel system. Fuel Tank Filler Pipe Cap The fuel tank filler pipe is equipped with a quarter-turn type fuel tank filler pipe cap. In order to install the fuel tank filler pipe cap, turn the fuel tank filler pipe cap clockwise until a clicking noises is heard. A built-in device indicates that the fuel tank filler pipe cap is fully seated. A fuel filler cap that is not fully seated, may cause a malfunction in the emission system. The fuel fill cap is also part of the (ORVR) EVAP system and has a tether connected to the fuel fill door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 6220 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 6221 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 6222 Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information INFORMATION Bulletin No.: 04-06-04-047I Date: August 17, 2009 Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - U.S. Only Models: 2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010 HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only) Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from the use of TOP TIER Detergent Gasoline. Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline Intake valve: - 10,000 miles with Legal Minimum additive Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent Gasoline Standards: - Chevron - Chevron-Canada - QuikTrip - Conoco Phillips 66 - 76 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 6223 - Shell - Shell-Canada - Entec Stations located in the greater Montgomery, Alabama area. - MFA Oil Company located throughout Missouri. - Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa. The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky. Aloha Petroleum - Tri-Par Oil Company - Turkey Hill Minit Markets - Texaco - Petro-Canada - Sunoco-Canada - Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent requirements imposed by the EPA. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Where Can I find the Latest Information on TOP TIER Fuel and Retailers? On the web, please visit www.toptiergas.com for additional information and updated retailer lists. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi, BMW, General Motors, Honda, Toyota and Volkswagen. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 6224 Fuel: Technical Service Bulletins Fuel System - E85 Fuel Usage Precautions Bulletin No.: 05-06-04-035C Date: July 30, 2007 INFORMATION Subject: Usage of E85 Fuels in GM Vehicles Models: 1997-2008 GM Passenger Cars and Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 1997-2008 Isuzu NPR Commercial Medium Duty Trucks 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add the 2008 model year and additional engines with E85 capability. Please discard Corporate Bulletin Number 05-06-04-035B (Section 06 Engine/Propulsion System). Customer Interest in E85 Fuel As the retail price of gasoline increases, some locations in the country are seeing price differentials between regular gasoline and E85 where E85 is selling for substantially less than regular grade gasoline. One result of this is that some customers have inquired if they are able to use E85 fuel in non-E85 compatible vehicles. Only vehicles designated for use with E85 should use E85 blended fuel. E85 compatibility is designated for vehicles that are certified to run on up to 85% ethanol and 15% gasoline. All other gasoline engines are designed to run on fuel that contains no more than 10% ethanol. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Using E85 Fuels in Non-Compatible Vehicles General Motors is aware of an increased number of cases where customers have fueled non-FlexFuel designated vehicles with E85. Fueling non-FlexFuel designated vehicles with E85, or with fuels where the concentration of ethanol exceeds the ASTM specification of 10%, will result in one or more of the following conditions: Lean Driveability concerns such as hesitations, sags and/or possible stalling. SES lights due to OBD codes. Fuel Trim codes P0171 and/or P0174. Misfire codes (P0300). Various 02 sensor codes. Disabled traction control or Stability System disabled messages. Harsh/Firm transmission shifts. Fuel system and/or engine mechanical component degradation. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. If the dealer suspects that a non-FlexFuel designated vehicle brought in for service has been fueled with E85, the fuel in the vehicle's tank should be checked for alcohol content with tool J 44175. If the alcohol content exceeds 10% the fuel should be drained and the vehicle refilled with gasoline - preferably one of the Top Tier brands. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 6225 Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. A complete list of GM's FlexFuel vehicles can be found in this Service Bulletin, or at www.livegreengoyellow.com. E85 Compatible Vehicles The only E85 compatible vehicles produced by General Motors are shown. Only vehicles that are listed in the E85 Compatible Vehicles section of this bulletin and/or www.livegreengoyellow.com are E85 compatible. All other gasoline and diesel engines are NOT E85 compatible. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 6226 Fuel: Technical Service Bulletins Fuel - Top Tier Detergent Gasoline Information Bulletin No.: 04-06-00-047 Date: June 24, 2004 ADVANCED SERVICE INFORMATION Subject: Top Tier Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) Models: 2005 and Prior All General Motors Passenger Cars and Trucks (U.S. Only) A new class of gasoline, called Top Tier Detergent Gasoline, will be appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by four automotive companies. A description of the concept and benefits of Top Tier is provided in the following question and answer section. What is Top Tier Detergent Gasoline? Top Tier Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by four automotive companies that exceed the detergent requirements imposed by the EPA. Who developed Top Tier Detergent Gasoline standards? Top Tier Detergent Gasoline standards were developed by four automotive companies: BMW, General Motors, Honda and Toyota. Why was Top Tier Detergent Gasoline developed? Top Tier Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet Top Tier Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, Top Tier was developed to give fuel marketers the opportunity to differentiate their product. Why did the four automotive companies join together to develop Top Tier? All four corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of Top Tier Detergent Gasoline? Top Tier Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of Top Tier Detergent Gasoline will help reduce deposit related concerns. Who should use Top Tier Detergent Gasoline? All vehicles will benefit from using Top Tier Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from use of Top Tier Detergent Gasoline. Where can Top Tier Detergent Gasoline be purchased? The Top Tier program began on May 3, 2004. Some fuel marketers have already joined and are making plans to introduce Top Tier Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, a list of all fuel marketers meeting Top Tier standards will be made available. For now, look for the "Top Tier" designation at the gas pump. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 6227 Fuel: Testing and Inspection Alcohol concentrations more than 10 percent in fuel can be detrimental to fuel system components and may cause driveability problems such as hesitation, lack of power, stall, no start, etc. The problems may be due to fuel system corrosion and subsequent fuel filter plugging, deterioration of rubber components, and/or air-fuel mixture leaning. Various types and concentrations of alcohol are used in commercial fuel. Some alcohol is more detrimental to fuel system components than others. If an excessive amount of alcohol in the fuel is suspected as the cause of a driveability condition. Alcohol In Fuel Testing Procedure The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If alcohol contamination is suspected then use the following procedure to test the fuel quality. 1. Using a 100 ml specified cylinder with 1 ml graduation marks, fill the cylinder with fuel to the 90 ml mark. 2. Add 10 ml of water in order to bring the total fluid volume to 100 ml and install a stopper. 3. Shake the cylinder vigorously for 10 to 15 seconds. 4. Carefully loosen the stopper in order to release the pressure. 5. Re-install the stopper and shake the cylinder vigorously again for 10 to 15 seconds. 6. Put the cylinder on a level surface for approximately 5 minutes in order to allow adequate liquid separation. If alcohol is present in the fuel, the volume of the lower layer (which would now contain both alcohol and water) will be more than 10 ml. For example, if the volume of the lower layer is increased to 15 ml, this indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat more because this procedure does not extract all of the alcohol from the fuel. Particulate Contaminants In Fuel Testing Procedure The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If the sample appears cloudy, or contaminated with water (as indicated by a water layer at the bottom of the sample) use the following procedure to diagnose the fuel. 1. Using an approved fuel container, draw approximately 0.5 liter of fuel. 2. Place the cylinder on a level surface for approximately 5 minutes in order to allow settling of the particulate contamination. 3. Observe the fuel sample. If any physical contaminants or water are present, then clean the fuel system. Refer to Fuel System Cleaning. Particulate contamination will show up in various shapes and colors, such as sand will typically be identified by a white or light brown crystals, rubber particles typically as black and irregular. Any particles that do show up regardless of color or shape are not acceptable, and the entire fuel system should be thoroughly cleaned. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 6228 Fuel: Service and Repair CLEANING PROCEDURE NOTE: ^ Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages. IMPORTANT: ^ When flushing the fuel tank, the fuel and water mixture needs to be treated as a hazardous material. The material needs to be handled in accordance with all local, state and federal laws and regulations. ^ When ever the fuel tank is cleaned, the fuel pump fuel strainer must be inspected. If the fuel pump fuel strainer is contaminated, the fuel pump fuel strainer must be replaced and the fuel pump must be inspected. ^ Always maintain cleanliness when servicing fuel system components. 1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure. See: Fuel Tank/Service and Repair/Procedures 3. Remove the fuel tank. 4. Remove the fuel sender assembly. 5. Inspect the fuel pump inlet for dint and debris. If dirt and debris are found, the fuel pump needs to be replaced. 6. Flush fuel tank with hot water. 7. Pour the water out of the fuel sender assembly opening in the fuel tank. Rock the fuel tank in order to be sure that the removal of the water from the fuel tank is complete. 8. Allow tank to dry completely before reassembly. 9. Reinstall the fuel sender assembly. 10. Reinstall the fuel tank. 11. Replace the fuel filter. 12. Add fuel and reinstall the fuel tank filler pipe cap. 13. Reconnect the negative battery cable. 14. Inspect for leaks. 14.1. Turn the ignition ON for 2 seconds. 14.2. Turn the ignition OFF for 10 seconds. 14.3. Turn the ignition ON. 14.4. Inspect for fuel leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair RELIEF PROCEDURE Tools Required ^ J34730-1A Fuel Pressure Gauge ^ J34730-262 Fuel Pressure Gauge Fitting CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery terminal. IMPORTANT: Mount the fuel pressure gauge fitting below the belt to avoid contact with the belt. 2. Install the J 34730-262 fuel pressure gauge fitting adaptor to the fuel pressure connection. 3. Connect fuel pressure gauge J 34730-1A to the fuel gauge pressure fitting. Wrap a shop towel around the fuel pressure connection while connecting the fuel pressure gauge in order to avoid spillage. 4. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the fuel pressure gauge into an approved container. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Maintenance Cleaning Fuel Injector: Technical Service Bulletins Fuel System - Fuel Injector Maintenance Cleaning Bulletin No.: 04-06-04-051B Date: January 04, 2006 INFORMATION Subject: Maintenance Cleaning of Fuel Injectors Models: 2006 and Prior All General Motors Passenger Cars and Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years and update the name and part number of GM Fuel System Treatment. Please discard Corporate Bulletin Number 04-06-04-051A (Section 06 - Engine/Propulsion System). General Motors is aware that some companies are marketing tools, equipment and programs to support fuel injector cleaning as a preventative maintenance procedure. General Motors does not endorse, support or acknowledge the need for fuel injector cleaning as a preventative maintenance procedure. Fuel injector cleaning is approved only when performed as directed by a published GM driveability or DTC diagnostic service procedure. Due to variation in fuel quality in different areas of the country, the only preventative maintenance currently endorsed by GM regarding its gasoline engine fuel systems is the addition of GM Fuel System Treatment PLUS, P/N 88861011 (for U.S. ACDelco(R), use P/N 88861013) (in Canada, P/N 88861012), added to a tank of fuel at each oil change. Refer to Corporate Bulletin Number 03-06-04-030A for proper cleaning instructions. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications Voltage Voltage ECT between 50-95 degrees F (10-35 degrees C) Injector Voltage Reading 5.7 - 6.6 Volts Please refer to Fuel Injector Coil Test procedure. Resistance Ohms Resistance Ohms ECT between 50 - 95 degrees F (10 - 35 degrees C) Ohms 11.4-12.6 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 6239 Fuel Injector: Pressure, Vacuum and Temperature Specifications Fuel Injector Pressure Drop Fuel Injector Pressure Drop If the pressure drop value for each injector is within 1.5 psi of the average drop value the fuel injectors are flowing properly. Pressure Drop 1.5 psi Fuel Injector Balance Test Example (Typical) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 6240 Fuel Injector: Locations Top of the engine at each of the cylinder intake ports. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions Fuel Injector: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6243 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6244 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6245 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6246 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6247 Fuel Injector: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6248 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6249 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6250 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6251 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6252 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6253 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6254 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6255 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6256 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6257 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6258 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6259 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6260 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6261 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6262 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6263 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6264 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6265 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6266 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6267 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6268 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6269 Fuel Injector: Connector Views Fuel Injector 1 Fuel Injector 2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6270 Fuel Injector 3 Fuel Injector 4 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6271 Fuel Injector 5 Fuel Injector 6 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 6272 Fuel Injector: Description and Operation The MULTEC 2 MPFI fuel injector assembly is a solenoid operated device, Controlled by an on-board computer called the powertrain control module ( PCM), that meters fuel to a single engine cylinder. The PCM energizes the high-impedance (12.0 ohms) solenoid (2) to open a normally closed ball valve (3). This allows fuel to flow into the top of the injector (1), past the ball valve, and through a director plate at the injector outlet. The director plate has precision holes that control fuel flow, generating a spray of finely atomized fuel at the injector tip. Fuel from the injector tip is directed at the intake valve, causing it to become further atomized and vaporized before entering the combustion chamber. The eight digit part number (2) is identified on the fuel injector body (1). A four digit number build date code is located to the far left of the part number. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 6273 Fuel Injector: Service and Repair REMOVAL PROCEDURE NOTE: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method. IMPORTANT: Important the fuel injector is serviced as a complete assembly only. If the fuel injectors are found to be leaking, the engine oil may be contaminated with fuel. 1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Remove the fuel rail. 3. Remove the fuel injector retaining clips (1). 4. Remove the fuel injector (3) from the fuel rail. 5. Remove the fuel injector Upper O-ring (2). 6. Remove the fuel injector lower O-ring (4). INSTALLATION PROCEDURE IMPORTANT: Important each fuel injector is calibrated for a specific flow rate. Be sure to use the correct part number when ordering replacement fuel injectors. When replacing the fuel injector O-rings, be sure to install the brown O-ring in the lower position. The fuel injector lower O-ring uses a nylon collar, called the O-ring backup, to properly position the O-ring on the fuel injector. Be sure to Install the O-ring backup, or the sealing O-ring may move on the fuel injector when installing the fuel rail. If the sealing O-ring is not seated properly, a vacuum leak is possible and driveability complaints may occur. 1. Install the fuel injector Upper O-ring (2). 2. Install the fuel injector lower O-ring (4). 3. Install the fuel injector (3) into the fuel rail. 4. Install the fuel injector retaining clips (1). 5. Install the fuel rail. 6. Install the upper intake manifold. 7. Tighten the fuel filler cap. 8. Reconnect the negative battery cable. 9. Inspect for fuel leaks using the following procedure: 9.1. Turn ON the ignition for 2 seconds. 9.2. Then OFF the ignition for 10 seconds. 9.3. Turn ON the ignition. 9.4. Inspect for fuel leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation Fuel Line Coupler: Description and Operation CAUTION: In order to Reduce the Risk of Fire and Personal Injury: ^ if nylon fuel pipes are nicked, scratched or damaged during installation, Do Not attempt to repair the sections of the nylon fuel pipes. Replace them. ^ When installing new fuel pipes, Do Not hammer directly on the fuel harness body clips as it may damage the nylon pipes resulting in a possible fuel leak. ^ Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period. ^ Before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.) Quick-connect type fittings provide a simplified means of disconnecting and connecting fuel system components. Depending on the vehicle type, there are two types of quick-connect fittings. Each are used at different locations in the fuel system. Each type of quick-connect fitting consists of a unique female connector and a compatible male fuel pipe end. An O-ring is located inside the female connector, witch provides the fuel seal. Integral locking tabs or fingers hold the quick-connect fittings together. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Fuel Line Coupler: Service and Repair Metal Collar REMOVAL PROCEDURE Tools Required J 37088-A Fuel Line Quick-Connect Separator CAUTION: ^ Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. ^ Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. NOTE: ^ Before attempting any On-Vehicle Service, place a dry chemical (Class B) fire extinguisher near work area. ^ Cap the fittings and plug the holes when servicing the fuel system in order to prevent din and other contaminants from entering the open pipes and passages. IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Grasp both sides of the fitting. Twist the female connector 1/4 turn in each direction to loosen any dirt within the fitting. 3. Blow dirt out of the fitting using compressed air. 4. Choose the correct tool from J 37088-A tool set for the size of the fitting. Insert the tool into the female connector, then push inward to release the locking tabs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar > Page 6279 5. Pull the connection apart. NOTE: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required. 6. Using a clean shop towel, wipe off the male pipe end. 7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 1. Apply a few drops of clean engine oil to the male pipe end. 2. Push both sides of the fitting together to cause the retaining tabs to snap into place. 3. Once installed, pull on both sides of the fitting to make sure the connection is secure. 4. Tighten the fuel filler cap. 5. Reconnect the negative battery cable. 6. Inspect for leaks. 6.1. Turn the ignition ON for 2 seconds. 6.2. Turn the ignition OFF for 10 seconds. 6.3. Turn the ignition ON. 6.4. Inspect for fuel leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar > Page 6280 Fuel Line Coupler: Service and Repair Plastic Collar REMOVAL PROCEDURE CAUTION: ^ Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. ^ Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. NOTE: ^ Before attempting any On-Vehicle Service, place a dry chemical (Class B) fire extinguisher near work area. ^ Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages. IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Grasp both sides of the quick-connect fitting. Twist quick-connect fitting 1/4 turn in each direction to loosen any dirt within fitting. 3. Repeat for other fuel pipe fitting. 4. Blow out dirt from quick-connect fittings at both ends, using compressed air. 5. Squeeze plastic tabs of male end connector. 6. Pull connection apart. Repeat for the other fitting. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar > Page 6281 7. Wipe off the male pipe end using a clean shop towel. 8. Clean or replace components/assemblies as required. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 1. Apply a few drops of clean oil to the male pipe end. 2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs/fingers to make sure snap into place. 3. Pull on both sides of the quick connect fitting in order to make sure the connection is secure. 4. Tighten the fuel filler cap. 5. Reconnect negative battery cable. 6. Inspect for fuel leaks. 6.1. Turn the ignition ON for 2 seconds. 6.2. Turn the ignition OFF for 10 seconds. 6.3. Turn the ignition ON. 6.4. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications Fuel Pressure Regulator: Specifications Fuel Pressure Regulator Attaching Bolt 8.5 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Fuel Pressure Regulator Assembly Fuel Pressure Regulator: Description and Operation Fuel Pressure Regulator Assembly Fuel Pressure Regulator The fuel pressure regulator is a diaphragm-operated relief valve with fuel pump pressure on one side and manifold pressure on the other. The function of the fuel pressure regulator is to maintain the fuel pressure available to the fuel injectors at 3 times barometric pressure, adjusted for engine load. The fuel pressure regulator attaches to the fuel rail on the fuel return side and may be serviced separately. If the fuel pressure is too low, poor performance could result. If the pressure is to high, excessive odor and a Diagnostic Trouble Code (DTC) may result. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Fuel Pressure Regulator Assembly > Page 6287 Fuel Pressure Regulator: Description and Operation Pressure Regulator Assembly Fuel Pressure Regulator The fuel pressure regulator is a diaphragm-operated relief valve with fuel pump pressure on one side and manifold pressure on the other. The function of the fuel pressure regulator is to maintain the fuel pressure available to the fuel injectors at 3 times barometric pressure, adjusted for engine load. The fuel pressure regulator is mounted on the fuel rail and may be serviced separately. If the fuel pressure is too low, poor performance and DTC P0171 could result.If the pressure is too high, excessive odor and/or DTC P0172 may result. Refer to Fuel System Pressure Test. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 6288 Fuel Pressure Regulator: Service and Repair REMOVAL PROCEDURE 1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Disconnect the fuel pressure regulator vacuum line. 3. Remove the fuel pressure regulator retaining screw. 4. Using a shop towel to catch any spilled fuel, lift and twist the fuel pressure regulator in order to remove the fuel pressure regulator from the fuel rail. 5. Remove the retainer and spacer bracket from rail and discard. 6. Remove the fuel pressure regulator from the engine fuel return pipe. 7. Remove the fuel pressure regulator inlet 0-ring and discard. INSTALLATION PROCEDURE CAUTION: Connect the fuel return line before tightening the regulator attaching screw in order to prevent the regulator from rotating. Rotation of the regulator could damage the retainer and spacer bracket and lead to a fuel leak at the regulator inlet NOTE: ^ Do not use compressed air in order to test or clean a fuel pressure regulator as damage to the fuel pressure regulator may result. ^ Clean the fuel pressure regulator filter screen with gasoline if necessary. ^ Do not immerse the fuel pressure regulator in a solvent bath in order to prevent damage to the fuel pressure regulator. 1. Check the filter screen for contamination. If contaminated, replace the fuel pressure regulator. 2. Lubricate new pressure regulator inlet 0-ring with clean engine oil and install on regulator inlet. 3. Reinstall the fuel return pipe to regulator. 4. Install the new retainer and spacer bracket into slot on fuel rail. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the pressure regulator to fuel rail. Tighten Tighten engine fuel return pipe nut to 17 N.m (13 lb ft). 6. Reconnect the fuel pressure regulator vacuum line. 7. Reinstall the pressure regulator attaching screw. Tighten Tighten pressure regulator attaching screw to 8.5 N.m (76 lb in). 8. Inspect and verify that retainer and spacer bracket is engaged in slots in fuel rail. Grasp and pull on regulator to ensure that it is properly seated. 9. Reinstall the fuel filler cap. 10. Reconnect the battery negative battery cable. 11. Inspect the fuel system. 11.1. Turn the ignition ON for 2 seconds. 11.2. Turn the ignition OFF for 10 seconds. 11.3. Turn the ignition ON. 11.4. Check for fuel leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure - Correct Operating Range Fuel Pressure: Technical Service Bulletins Fuel Pressure - Correct Operating Range File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-018 Date: May, 1999 INFORMATION Subject: Correct Fuel Pressure Operating Range Models: 2000 Buick Century 2000 Chevrolet Impala, Lumina, Malibu, Monte Carlo, Venture 2000 Oldsmobile Alero, Silhouette 2000 Pontiac Grand Am, Grand Prix, Montana with 3.1 L or 3.4 L V6 Engine (VINs J, E - RPOs LG8, LA1) All 2000 model year 3.1 L and 3.4 L engines have a revised fuel pressure regulator and Multec II fuel injectors. The fuel system operating pressure is 358-405 kPa (52-59 psi) on these applications. Important: ^ This regulator is NOT interchangeable with past model applications. When replacement is necessary for the above listed applications, use only regulator P/N 17113622. ^ Installing regulators other than the above listed part number in these applications may result in a change in engine performance and/or driveability concerns. Refer to the Engine Controls subsection of the Service Manual for complete diagnostic and repair information on fuel system related concerns. Parts Information Part Number Description 17113622 Fuel Pressure Regulator Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > Page 6294 Fuel Pressure: Specifications Fuel Pressure Fuel Pressure Fuel Pressure 52-59 psi Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis Fuel Pressure: Testing and Inspection Fuel System Diagnosis Diagnostic Chart (Part 1 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 6297 Diagnostic Chart (Part 2 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 6298 Diagnostic Chart (Part 3 Of 3) SYSTEM DESCRIPTION Proper fuel pressure is necessary to maintain efficient engine operation and emission levels, if fuel pressure is not within specifications vehicle driveablity may be affected or emission levels elevated. The fuel system contains the following components: ^ Fuel strainer ^ Modular fuel sender assembly ^ Fuel filter ^ Fuel feed pipes and hoses ^ Fuel pressure regulator ^ Fuel rail ^ Fuel injectors ^ Fuel return pipes and hoses TEST DESCRIPTION The numbers below refer to the step numbers on the diagnostic table. 2. Tests the fuel systems ability to achieve a specific fuel pressure range. It may be necessary to cycle the fuel pump several times to achieve the pressure range. 6. A fuel system that drops more than 5 psi in 10 minutes has a leak in one or more areas. 8. Tests the fuel systems ability to maintain a specific fuel pressure. It may be necessary to cycle the fuel pump several times to achieve the pressure range. 9. Fuel pressure that drops-off during acceleration, cruise, or hard cornering may cause a lean condition. A lean condition can cause a loss of power, surging, or misfire and may be diagnosed using a scan tool. If an extremely lean condition occurs, the oxygen sensors may drop below 500 mV and the fuel injector pulse width will increase. 13. When the engine is at idle, the manifold pressure is low, high vacuum. This low pressure, high vacuum, is applied to the fuel pressure regulator diaphragm, the result is lower fuel pressure. The fuel pressure at idle will vary slightly as the pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in Step 2 with the engine OFF. 14. This test determines if the high fuel pressure is due to a restricted fuel return pipe or fuel pressure regulator. A rich condition may cause a DTC P0132 or DTC P0172 to set. Driveability conditions associated with rich conditions can include hard starting, followed by black smoke, and a Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 6299 strong sulfur smell in the exhaust. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 6300 Fuel Pressure: Testing and Inspection Fuel System Pressure Test Diagnostic Chart (Part 1 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 6301 Diagnostic Chart (Part 2 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 6302 Diagnostic Chart (Part 3 Of 3) SYSTEM DESCRIPTION Proper fuel pressure is necessary to maintain efficient engine operation and emission levels, if fuel pressure is not within specifications vehicle driveablity may be affected or emission levels elevated. The fuel system contains the following components: ^ Fuel strainer ^ Modular fuel sender assembly ^ Fuel filter ^ Fuel feed pipes and hoses ^ Fuel pressure regulator ^ Fuel rail ^ Fuel injectors ^ Fuel return pipes and hoses TEST DESCRIPTION The numbers below refer to the step numbers on the diagnostic table. 2. Tests the fuel systems ability to achieve a specific fuel pressure range. It may be necessary to cycle the fuel pump several times to achieve the pressure range. 6. A fuel system that drops more than 5 psi in 10 minutes has a leak in one or more areas. 8. Tests the fuel systems ability to maintain a specific fuel pressure. It may be necessary to cycle the fuel pump several times to achieve the pressure range. 9. Fuel pressure that drops-off during acceleration, cruise, or hard cornering may cause a lean condition. A lean condition can cause a loss of power, surging, or misfire and may be diagnosed using a scan tool. If an extremely lean condition occurs, the oxygen sensors may drop below 500 mV and the fuel injector pulse width will increase. 13. When the engine is at idle, the manifold pressure is low, high vacuum. This low pressure, high vacuum, is applied to the fuel pressure regulator diaphragm, the result is lower fuel pressure. The fuel pressure at idle will vary slightly as the pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in Step 2 with the engine OFF. 14. This test determines if the high fuel pressure is due to a restricted fuel return pipe or fuel pressure regulator. A rich condition may cause a DTC P0132 or DTC P0172 to set. Driveability conditions associated with rich conditions can include hard starting, followed by black smoke, and a Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 6303 strong sulfur smell in the exhaust. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6308 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6309 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6310 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6311 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6312 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6313 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6314 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6315 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6316 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6317 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6318 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6319 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6320 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6321 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6322 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6323 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6324 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6325 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6326 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6327 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6328 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6329 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6330 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6331 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6332 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6333 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 6334 Fuel Pump Relay: Service and Repair REMOVAL PROCEDURE 1. Turn the ignition OFF. 2. Remove the under hood electrical center cover. 3. Remove the fuel pump relay. INSTALLATION PROCEDURE 1. Install the fuel pump relay. 2. Install the under hood electrical center cover. 3. Turn the ignition ON. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation The fuel pump strainer attaches to the lower end of the modular fuel sender assembly. The fuel pump strainer is made of woven plastic. The functions of the fuel pump strainer is to filter contaminants and to wick fuel. The life of the fuel pump strainer is generally considered to be that of the fuel pump, is self-cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water, in which case the tank should be thoroughly cleaned and replace the plugged fuel pump strainer with a new one. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation > Page 6338 Fuel Pump Pickup Filter: Service and Repair REMOVAL PROCEDURE IMPORTANT: Always maintain cleanliness when servicing fuel system components. Fuel Sender Assembly 1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Remove the fuel sender assembly. 3. Note strainer (3) position for future reference. 4. Support the reservoir with one hand and grasp the strainer with the other hand. 5. Use a screwdriver to pry the strainer ferrule off the reservoir. 6. Discard the strainer. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation > Page 6339 1. Install the new strainer (4) to the reservoir. 2. Support the reservoir with one hand and grasp the strainer with the other hand twisting the strainer into position. 3. Reinstall the fuel sender assembly. 4. Reconnect the negative battery cable. 5. Inspect for fuel leaks. 5.1. Turn the ignition ON for 2 seconds. 5.2. Turn the ignition OFF for 10 seconds. 5.3. Turn the ignition ON. 5.4. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications Fuel Rail: Specifications Fuel Rail Attaching Nuts or Bolts 10 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 6343 Fuel Rail: Description and Operation The fuel rail assembly is made up of the left hand rail (5), which delivers fuel to the even cylinders (2,4,6); the right hand rail (1), which delivers fuel to the odd cylinders (1 3,5). The fuel injectors (4), and the fuel pressure regulator assembly (3) which are mounted to the lower section of the intake manifold and distributes fuel to the cylinders through the individual injectors. Fuel is delivered to the fuel inlet tube (2) of the fuel rail by the fuel pipes. The fuel then goes through the fuel rail to the fuel pressure regulator. The fuel pressure regulator maintains a constant fuel pressure at the fuel injectors. Remaining fuel is then returned to the fuel tank. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 6344 Fuel Rail: Service and Repair REMOVAL PROCEDURE An eight digit identification number is stamped on the left hand fuel rail (fueling even cylinders 2,4,6). Refer to this number if servicing or part replacement is required. CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector O-rings in the proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring in the upper position and the brown O-ring in the lower position on the fuel injector. The O-rings are the same size but are made of different materials. IMPORTANT: Important when servicing the fuel rail assembly, precautions must be taken to prevent dirt and other contaminants from entering the fuel passages. It is recommended that the fittings be capped, and the holes be plugged during servicing. 1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Remove the upper intake manifold. 3. Disconnect the engine fuel feed pipe at fuel rail. 4. Disconnect the engine fuel return pipe at the fuel pressure regulator. 5. Remove the fuel feed pipe and fuel return pipe O-rings and discard. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 6345 6. Disconnect the main injector harness electrical connector. 7. Pull up the lock release of the fuel injector connector (1). 8. Depress the the lock tab (1) and lift the connector from the injector. 9. Remove the injector electrical harness from the fuel rail. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 6346 10. Disconnect the coolant temperature sensor electrical connector. 11. Remove the fuel rail retaining bolts. 12. Remove the fuel rail assembly. 13. Remove the injector O-ring seal from spray tip end of each injector. Discard seals. With the O-ring removed, the O-ring backup may slip off of the injector. Be sure to retain the O-ring backup for reuse. INSTALLATION PROCEDURE NOTE: ^ Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, the injector O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination. ^ Do not use the compressed air to clean the fuel rail assembly as this may damage the fuel rail components. ^ Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 6347 1. Install The fuel rail assembly into the intake manifold. Tilt rail assembly to install injectors. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel rail attaching bolts. Tighten Tighten the fuel rail attaching bolt to 10 N.m (7 lb ft). 3. Connect the coolant temperature sensor electrical connector. 4. Install the injector electrical harness to the fuel rail. 5. Connect the injector electrical connectors (2). 6. Push the slide lock into the locked position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 6348 7. Connect the main injector harness electrical connector. 8. Install new O-rings on the fuel teed pipe and fuel return pipe. 9. Connect the fuel feed pipe at the fuel rail. Tighten Tighten the engine fuel feed pipe nut to 17 N.m (13 lb ft). 10. Connect the fuel return pipe at the fuel pressure regulator. Tighten Tighten the engine fuel return pipe nut to 17 N.m (13 lb ft). 11. Install the upper intake manifold. 12. Connect the negative battery cable. 13. Inspect for fuel leaks using the following procedure: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 6349 13.1. Turn ON the ignition for 2 seconds. 13.2. Turn OFF the ignition, for 10 seconds. 13.3. Turn ON the ignition. 13.4. Inspect for fuel leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation > Fuel Feed and Fuel Return Pipes Fuel Return Line: Description and Operation Fuel Feed and Fuel Return Pipes The fuel feed and fuel return pipes carry fuel from the modular fuel sender assembly to the fuel injection system and back to the modular fuel sender assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation > Fuel Feed and Fuel Return Pipes > Page 6354 Fuel Return Line: Description and Operation Nylon Fuel Pipes CAUTION: In order to Reduce the Risk of Fire and Personal Injury: ^ If nylon fuel pipes are nicked, scratched or damaged during installation, Do Not attempt to repair the sections of the nylon fuel pipes. Replace them. ^ When installing new fuel pipes, Do Not hammer directly on the fuel harness body clips as it may damage the nylon pipes resulting in a possible fuel leak. ^ Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period. ^ Before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.) Nylon fuel pipes are designed to perform the same job as the steel or rubber fuel lines they replace. Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives and changes in temperature. There are two sizes used: 3/8" ID for the fuel feed, and 5/16" ID for the fuel return and are used on the modular sender. Nylon fuel pipes are somewhat flexible and can be formed around gradual turns. However, if forced into sharp bends, nylon pipes will kink and restrict fuel flow. Also, once exposed to fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Special care should be taken when working on a vehicle with nylon pipes. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Fuel Feed and Fuel Return Pipes Fuel Supply Line: Description and Operation Fuel Feed and Fuel Return Pipes The fuel feed and fuel return pipes carry fuel from the modular fuel sender assembly to the fuel injection system and back to the modular fuel sender assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Fuel Feed and Fuel Return Pipes > Page 6360 Fuel Supply Line: Description and Operation Nylon Fuel Pipes CAUTION: In order to Reduce the Risk of Fire and Personal Injury: ^ If nylon fuel pipes are nicked, scratched or damaged during installation, Do Not attempt to repair the sections of the nylon fuel pipes. Replace them. ^ When installing new fuel pipes, Do Not hammer directly on the fuel harness body clips as it may damage the nylon pipes resulting in a possible fuel leak. ^ Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period. ^ Before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.) Nylon fuel pipes are designed to perform the same job as the steel or rubber fuel lines they replace. Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives and changes in temperature. There are two sizes used: 3/8" ID for the fuel feed, and 5/16" ID for the fuel return and are used on the modular sender. Nylon fuel pipes are somewhat flexible and can be formed around gradual turns. However, if forced into sharp bends, nylon pipes will kink and restrict fuel flow. Also, once exposed to fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Special care should be taken when working on a vehicle with nylon pipes. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Filter to Engine Fuel Supply Line: Service and Repair Filter to Engine REMOVAL PROCEDURE Tool Required J 37088-A tool set, Fuel Pipe Quick-Connect Separator CAUTION: In order to Reduce the Risk of Fire and Personal Injury: ^ If nylon fuel pipes are nicked, scratched or damaged during installation, Do Not attempt to repair the sections of the nylon fuel pipes. Replace them. ^ When installing new fuel pipes, Do Not hammer directly on the fuel harness body clips as it may damage the nylon pipes resulting in a possible fuel leak. ^ Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period. ^ Before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.) NOTE: ^ Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle. ^ Replace the EVAP pipes and hoses with the original equipment or parts that meet the GM specifications for those parts. The replacement EVAP pipe must have the same type of fittings as the original pipe in order to ensure the integrity of the connection. When replacing EVAP hoses, use only reinforced fuel-resistant hose identified with the word Fluoroelastomer or GM 6163-M on the hose. The inside hose diameter must match the outside pipe diameter. Do not use rubber hose within 100 mm (4 in) of any part of the exhaust system or within 254 mm (10 in) of the catalytic converter. ^ Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages. IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Clean all engine fuel pipe connections. 3. Clean areas surrounding the engine fuel pipe connections. 4. Disconnect the fuel feed and fuel return pipe quick-connect fitting in the engine compartment. 5. Raise the vehicle. 6. Disconnect the fuel return pipe quick-connect fitting in front of the fuel tank. 7. Disconnect the fuel feed pipe threaded fitting on the engine-side of the in-pipe fuel filter. 8. Cap the in-pipe fuel filter pipe, the fuel feed pipe, and the fuel return pipe as needed to stop any fuel leakage. 9. Remove the fuel feed, fuel return, and EVAP pipe attaching hardware and the fuel feed, fuel return, and EVAP pipes. 10. Note the position of the fuel and EVAP pipes and the fuel and EVAP pipe attaching hardware for installation. 11. Inspect the pipes for bends, kinks and cracks. 12. Repair or replace the pipe or pipes as required. INSTALLATION PROCEDURE CAUTION: In order to Reduce the Risk at Fire and Personal Injury: If nylon fuel pipes are nicked, scratched or damaged during installation, they must be replaced. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Filter to Engine > Page 6363 NOTE: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware. Do not repair sections of fuel pipes. NOTE: ^ Secure the fuel pipes to the frame in order to prevent chafing. Maintain a minimum of 13 mm (1/2 inch) clearance around a pipe in order to prevent contact and chafing. Maintain a minimum of 19 mm (3/4 inch) around any moving part. ^ Do not allow the fuel pipes to come into contact with the fuel tank or underbody. 1. Install the new fuel feed, fuel return, and EVAP pipes and the fuel and EVAP pipe attaching hardware as noted during removal. IMPORTANT: If fuel line bundle attaching hardware is damaged or broken replace it. 2. Remove the caps from the in-pipe fuel filter pipe, the fuel feed pipe, and the fuel return pipe. 3. Connect the fuel return pipe quick-connect fitting in front of the fuel tank. NOTE: Refer to Fastener Notice in Service Precautions. 4. Connect the fuel feed pipe threaded fitting at the outlet of the in pipe fuel filter. Tighten Tighten The in-pipe fuel filter fitting to 30 N.m (22 lb ft). 5. Connect the fuel teed, and fuel return pipe quick-connect fittings in the engine compartment. 6. Inspect and make sure all of the fuel pipe bundle clips, and fasteners are properly installed. 7. Lower the vehicle. 8. Tighten the fuel fill cap. 9. Reconnect the negative battery cable. 10. Inspect for fuel leaks. 10.1. Turn the ignition ON for 2 seconds. 10.2. Turn the ignition OFF for 10 seconds. 10.3. Turn the ignition ON. 10.4. Inspect for fuel leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Filter to Engine > Page 6364 Fuel Supply Line: Service and Repair Filter to Tank REMOVAL PROCEDURE CAUTION: In order to Reduce the Risk of Fire and Personal Injury: ^ If nylon fuel pipes are nicked, scratched or damaged during installation, Do Not attempt to repair the sections of the nylon fuel pipes. Replace them. ^ When installing new fuel pipes, Do Not hammer directly on the fuel harness body clips as it may damage the nylon pipes resulting in a possible fuel leak. ^ Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period. ^ Before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.) NOTE: ^ Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle. ^ Replace the EVAP pipes and hoses with the original equipment or parts that meet the GM specifications for those parts. The replacement EVAP pipe must have the same type of fittings as the original pipe in order to ensure the integrity of the connection. When replacing EVAP hoses, use only reinforced fuel-resistant hose identified with the word Fluoroelastomer or GM 6163-M on the hose. The inside hose diameter must match the outside pipe diameter. Do not use rubber hose within 100 mm (4 in) of any part of the exhaust system or within 254 mm (10 in) of the catalytic converter. ^ Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages. IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure. See: Fuel Tank/Service and Repair/Procedures 3. Remove the fuel tank. 4. Disconnect the fuel feed, fuel return, and EVAP pipe quick-connect fittings at the fuel sender assembly. 5. Cap the fuel sender fuel pipes and the in-pipe fuel filter pipes as needed to stop any fuel leakage 6. Remove the fuel feed, fuel return, and EVAP pipe attaching hardware. 7. Remove the fuel feed, fuel return, and EVAP pipes. 8. Note the position of the fuel, and EVAP pipes and the fuel and EVAP pipe attaching hardware for installation. INSTALLATION PROCEDURE CAUTION: In order to Reduce the Risk Of Fire and Personal Injury: If nylon fuel pipes are nicked, scratched or damaged during installation, they must be replaced. NOTE: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware. Do not repair sections of fuel pipes. NOTE: ^ Secure the fuel pipes to the frame in order to prevent chafing. Maintain a minimum of 13 mm (1/2 inch) clearance around a pipe in order to prevent contact and chafing. Maintain a minimum of 19 mm (3/4 inch) around any moving part. ^ Do not allow the fuel pipes to come into contact with the fuel tank or underbody. 1. Install the new fuel feed, fuel return, and EVAP pipes and the fuel and EVAP pipe attaching hardware as noted during removal. 2. Remove the caps from the in-pipe fuel filter pipes and the fuel sender fuel pipes. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Filter to Engine > Page 6365 3. Connect the fuel feed, fuel return, and EVAP pipe quick-connect fittings at the fuel sender assembly. 4. Inspect and make sure all of the fuel pipe bundle clips, and fasteners are properly installed. 5. Install the fuel tank. 6. Lower the vehicle. 7. Add fuel and reinstall the fuel fill pipe cap. 8. Reconnect the negative battery cable. 9. Inspect for fuel leaks. 9.1. Turn the ignition ON for 2 seconds. 9.2. Turn the ignition OFF for 10 seconds. 9.3. Turn the ignition ON. 9.4. Inspect for fuel leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Specifications Fuel Filler Hose: Specifications Fuel Filler Pipe Attaching Screws 10 Nm Fuel Filler Pipe Frame Attaching Screws 10 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Specifications > Page 6370 Fuel Filler Hose: Service and Repair REMOVAL PROCEDURE NOTE: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages. IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Relieve the fuel system pressure. Refer to Fuel System Pressure Test. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting. 3. Loosen the fuel filler hose clamp at the fuel tank. 4. Loosen the fuel filler hose clamp at the fuel filler pipe. 5. Remove the fuel filler hose. 6. Remove the fuel filler pipe attaching screw from the under body. 7. Remove the fuel filler pipe attaching screws from the fuel filler pipe access panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Specifications > Page 6371 8. Remove the fuel filler pipe. INSTALLATION PROCEDURE 1. Install the fuel filler pipe. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel filler pipe attaching screws to the fuel filler pipe access panel. Tighten The fuel filler pipe attaching screws to 10 N.m (88 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Specifications > Page 6372 3. Install the fuel filler pipe attaching screw to the under body. Tighten The fuel filler pipe attaching screw to 10 N.m (88 lb in). 4. Connect the vapor recirculation line at the fuel filler pipe. 5. Install the fuel filler hose. 6. Tighten the fuel filler hose clamp at the fuel tank. 7. Tighten the fuel filler hose clamp at the fuel filler pipe. 8. Inspect and make sure filler hose is fully seated on fuel tank port, and fuel filler pipe. 9. Make sure clamp is properly located on tank port between the bead and tank. Tighten Tighten the fuel tank filler hose clamps to 2.5 N.m (22 lb in). 10. Lower the vehicle. 11. Tighten the fuel filler cap. 12. Reconnect the negative battery cable. 13. Inspect for fuel leaks using the following procedure: 13.1. Turn ON the ignition, for 2 seconds. 13.2. Turn OFF the ignition, for 10 seconds. 13.3. Turn ON the ignition. 13.4. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Service and Repair Fuel Filler Neck: Service and Repair Fuel Tank Filler Pipe Housing Replacement (Impala) Removal Procedure 1. Open the fuel filler door. 2. Remove the fuel filler cap. 3. Remove the bolts from the fuel filler pocket at the fuel filler neck. 4. Remove the bolts from the fuel filler pocket. 5. Remove the fuel filler pocket. Installation Procedure 1. Install the fuel filler pocket to the fuel filler neck. 2. Press until the pocket is fully seated. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the fuel filler neck bolts. Tighten the fuel filler neck bolts to 5 Nm (44 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Service and Repair > Page 6376 4. Install the fuel filler pocket bolts. Tighten the fuel filler pocket bolts to 5 Nm (44 lb in). 5. Replace the fuel filler cap. 6. Close the fuel filler door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Mounted in the fuel tank. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6382 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6383 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6384 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6385 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6386 Fuel Gauge Sender: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6387 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6388 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6389 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6390 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6391 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6392 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6393 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6394 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6395 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6396 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6397 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6398 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6399 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6400 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6401 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6402 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6403 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6404 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6405 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6406 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6407 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6408 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Page 6409 Fuel Gauge Sender: Description and Operation The fuel level sensor consists of the following components: float, the wire float arm, and the ceramic resistor card. The fuel level sensor is mounted on the modular fuel sender assembly and is used as an input to the PCM. The PCM uses this information as a fuel level input for Various diagnostics. In addition the PCM transmits the fuel level over the Class II communication circuit to the IP cluster. This information is used for the IP fuel gauge, and low fuel warning indicator if applicable. Fuel Level Sensor The Fuel Level Sensor(4) is mounted on the Modular Fuel Sender Assembly(s). The PCM uses the fuel level input for various diagnosis including the EVAP System. In addition the PCM transmits the fuel level over the Class II communication circuit to the IP Cluster. The low fuel level message may not appear if other messages are being commanded, such as the rear deck lid, driver or passenger doors ajar. Ensure that all doors and compartment lids are completely closed. For further information regarding the Fuel Level Sensor refer to Fuel Metering Modes of Operation. See: Description and Operation/Fuel Metering/Fuel Metering Modes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Page 6410 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Remove the modular fuel sender assembly. 3. Remove the fuel level sensor (5) from the modular fuel sender. INSTALLATION PROCEDURE 1. Reinstall the fuel level sensor (5) to modular fuel sender. 2. Reinstall the fuel sender assembly. 3. Tighten the fuel filler cap. 4. Reconnect the negative battery cable. 5. Inspect for fuel leaks. 5.1. Turn the ignition ON for 2 seconds 5.2. Turn the ignition OFF for 10 seconds. 5.3. Turn the ignition ON. 5.4. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-028 > Aug > 00 > Fuel Tank - Bang/Slosh Noise Fuel Tank Mounting Straps: Customer Interest Fuel Tank - Bang/Slosh Noise File In Section: 06 - Engine/Propulsion System Bulletin No.: 00-06-04-028 Date: August, 2000 TECHNICAL Subject: Bang/Slosh From Rear of Vehicle (Install Fuel Tank Insulators) Models: 2000 Buick Century, Regal 2000 Chevrolet Impala, Monte Carlo Condition Some customers may comment on a bang/slosh type noise coming from the rear of the vehicle. This noise will be most noticeable when the vehicle comes to a stop or during parking lot maneuvers. Customers may also comment that the noise will not occur when the fuel tank is full. Cause The noise may be caused by fuel in the fuel tank sloshing when the fuel level is below full. This noise is transferred through the rear seat and storage area due to hard contact between the fuel tank and the floorpan. Correction Install insulator pads (P/N 88895867) to the top of the fuel tank and to the fuel straps, using the following service procedure: 1. Remove the fuel tank. Refer to the Fuel Tank Replacement Procedure in the Engine Controls sub-section of the Service Manual. 2. Remove the old insulator pads from the top of the fuel tank and clean the insulator pad mounting surfaces with a suitable cleaner. Important: Some of the fuel tanks and fuel tank straps may have a thinner insulator pad already located at one or more of the installation points. Remove the original pads to ensure proper adhesion of the new insulator pads. 3. Clean the fuel tank straps with a suitable cleaner. 4. Using a utility knife, cut the insulator pads (P/N 88895867) as follows: ^ Cut 5 pieces measuring 63.5 mm X 63.5 mm (2 1/2 in X 2 1/2 in) for use on the top of the fuel tank. ^ Cut 8 pieces measuring 38.1 mm X 63.5 mm (1 1/2 in X 2 1/2 in) for use on the fuel tank straps. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-028 > Aug > 00 > Fuel Tank - Bang/Slosh Noise > Page 6419 5. Install the insulator pads to the top of the fuel tank as shown in Figure 1. 6. Install the insulator pads to the fuel tank straps as shown in Figure 2. 7. Install the fuel tank to the vehicle. Refer to the Fuel Tank Replacement Procedure in the Engine Controls sub-section of the Service Manual. Parts Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-028 > Aug > 00 > Fuel Tank - Bang/Slosh Noise > Page 6420 Warranty Information For vehicles repaired under warranty, use: Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-06-04-028 > Aug > 00 > Fuel Tank - Bang/Slosh Noise Fuel Tank Mounting Straps: All Technical Service Bulletins Fuel Tank - Bang/Slosh Noise File In Section: 06 - Engine/Propulsion System Bulletin No.: 00-06-04-028 Date: August, 2000 TECHNICAL Subject: Bang/Slosh From Rear of Vehicle (Install Fuel Tank Insulators) Models: 2000 Buick Century, Regal 2000 Chevrolet Impala, Monte Carlo Condition Some customers may comment on a bang/slosh type noise coming from the rear of the vehicle. This noise will be most noticeable when the vehicle comes to a stop or during parking lot maneuvers. Customers may also comment that the noise will not occur when the fuel tank is full. Cause The noise may be caused by fuel in the fuel tank sloshing when the fuel level is below full. This noise is transferred through the rear seat and storage area due to hard contact between the fuel tank and the floorpan. Correction Install insulator pads (P/N 88895867) to the top of the fuel tank and to the fuel straps, using the following service procedure: 1. Remove the fuel tank. Refer to the Fuel Tank Replacement Procedure in the Engine Controls sub-section of the Service Manual. 2. Remove the old insulator pads from the top of the fuel tank and clean the insulator pad mounting surfaces with a suitable cleaner. Important: Some of the fuel tanks and fuel tank straps may have a thinner insulator pad already located at one or more of the installation points. Remove the original pads to ensure proper adhesion of the new insulator pads. 3. Clean the fuel tank straps with a suitable cleaner. 4. Using a utility knife, cut the insulator pads (P/N 88895867) as follows: ^ Cut 5 pieces measuring 63.5 mm X 63.5 mm (2 1/2 in X 2 1/2 in) for use on the top of the fuel tank. ^ Cut 8 pieces measuring 38.1 mm X 63.5 mm (1 1/2 in X 2 1/2 in) for use on the fuel tank straps. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-06-04-028 > Aug > 00 > Fuel Tank - Bang/Slosh Noise > Page 6426 5. Install the insulator pads to the top of the fuel tank as shown in Figure 1. 6. Install the insulator pads to the fuel tank straps as shown in Figure 2. 7. Install the fuel tank to the vehicle. Refer to the Fuel Tank Replacement Procedure in the Engine Controls sub-section of the Service Manual. Parts Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-06-04-028 > Aug > 00 > Fuel Tank - Bang/Slosh Noise > Page 6427 Warranty Information For vehicles repaired under warranty, use: Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Tank Mounting Straps: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Tank Mounting Straps: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 6433 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Tank Mounting Straps: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 6439 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications Fuel Tank Unit: Specifications Fuel Sender Access Panel Nut 10 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 6443 Fuel Tank Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 6444 Fuel Tank Unit: Service and Repair REMOVAL PROCEDURE CAUTION: Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a trunk. To reduce the risk of fire and increased exposure to vapors: ^ Use forced air ventilation such as a fan set outside of the trunk. ^ Plug or cap any fuel system openings in order to reduce fuel vapor formation. ^ Clean up any spilled fuel immediately. ^ Avoid sparks and any source of ignition. ^ Use signs to alert others in the work area that fuel system work is in process. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections IMPORTANT: ^ For rear compartment (trunk) accessible fuel sender assemblies, completely remove the rear compartment carpet before removing the fuel sender access panel. ^ Always replace the fuel sender O-rings when reinstalling the fuel sender assembly. ^ The modular fuel sender assembly will spring-up when the snap ring is removed. ^ Always maintain cleanliness when servicing fuel system components. 1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Remove the rear compartment trim panel. 3. Remove the nuts retaining the fuel sender access panel. 4. Remove the fuel sender access panel. 5. Disconnect the fuel tank pressure sensor electrical connector. 6. Disconnect the fuel sender electrical connector. 7. Clean the fuel pipes, and fuel sender assembly to prevent possible fuel contamination during removal. 8. Disconnect the quick-connect fittings at the fuel sender assembly. 9. Remove the fuel sender retaining snap ring. 10. Remove the modular fuel sender assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 6445 11. Clean the fuel sender assembly O-ring sealing surfaces. 12. Inspect the fuel sender assembly O-ring sealing surfaces. INSTALLATION PROCEDURE NOTE: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware. Do not repair sections of fuel pipes. IMPORTANT: ^ Care should be taken not to fold over or twist the fuel pump strainer when installing the fuel sender assembly, as this will restrict fuel flow. Also, assure that the fuel pump strainer does not block full travel of float arm. ^ Be sure that the fuel sender assembly retaining snap ring is fully seated within the tab slots on the fuel tank. 1. Position the new fuel sender assembly O-ring on the fuel tank. 2. Install the fuel sender assembly into the fuel tank. 3. Install the fuel sender assembly retaining snap ring, while holding the fuel sender in place. 4. Connect the fuel sender electrical connector. 5. Connect the fuel tank pressure sensor electrical connector. 6. Connect the quick-connect fittings at the fuel sender assembly. 7. Install the fuel filler cap. 8. Connect the negative battery cable. 9. Inspect for leaks using the following procedure: 9.1. Turn ON the ignition, for 2 seconds. 9.2. Turn OFF the ignition, for 10 seconds. 9.3. Turn ON the ignition. 9.4. Inspect for leaks. 10. Install the fuel sender access panel. NOTE: Refer to Fastener Notice in Service Precautions. 11. Reinstall the nuts retaining the fuel sender access panel. Tighten Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 6446 Tighten the fuel sender access panel nuts to 10 N.m (88 lb in) 12. Install the rear compartment trim panel. 13. Install the spare tire, the jack, and the spare tire cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control Motor (IAC): Specifications Idle Air Control Valve Attaching Screws 3 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations > Idle Air Control (IAC) Valve Idle Air Control Motor (IAC): Locations Idle Air Control (IAC) Valve Left Front Of Engine Top of the engine, front of the throttle assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations > Idle Air Control (IAC) Valve > Page 6452 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions Idle Air Control Motor (IAC): Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6455 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6456 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6457 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6458 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6459 Idle Air Control Motor (IAC): Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6460 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6461 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6462 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6463 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6464 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6465 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6466 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6467 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6468 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6469 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6470 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6471 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6472 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6473 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6474 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6475 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6476 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6477 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6478 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6479 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6480 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6481 Idle Air Control Valve Motor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 6482 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 6483 Idle Air Control Motor (IAC): Description and Operation The purpose of the Idle Air Control (IAC) valve is to control engine idle speed, while preventing stalls due to changes in engine load. The AC valve, mounted in the throttle body, controls bypass air around the throttle plate. By moving a conical valve, known as a pintle, in (to decrease air flow) or out (to increase air flow), a controlled amount of air can move around the throttle plate. If RPM is too low, the PCM will retract the IAC pintle, resulting in more air being bypassed around the throttle plate to increase RPM. If RPM is too high, the PCM will extend the IAC pintle, allowing less air to be bypassed around the throttle plate, decreasing RPM. The IAC pintle moves in small steps called counts. During idle, the proper position of the AC pintle is calculated by the PCM based on battery voltage, coolant temperature, engine load, and engine RPM. If the RPM drops below a specified value, and the throttle plate is closed (TP sensor voltage is between 0.20-0.74), the PCM senses a near stall condition. The PCM will then calculate a new IAC pintle position to prevent stalls. If the IAC valve is disconnected and reconnected with the engine running, the idle RPM will be wrong. In this case, the IAC has to be reset. The IAC resets when the key is cycled ON then OFF. When servicing the IAC, it should only be disconnected or connected with the ignition OFF in order to keep from having to reset the IAC. The position of the IAC pintle affects engine start up and the idle characteristics of the vehicle. If the IAC pintle is open fully, too much air will be allowed into the manifold. This results in high idle speed, along with possible hard starting and a lean air/fuel ratio. DTC P0507 may set. If the IAC pintle is stuck closed, too little air will be allowed in the manifold. This results in a low idle speed, along with possible hard starting and a rich air/fuel ratio. DTC P0506 may set. If the IAC pintle is stuck part way open, the idle may be high or low and will not respond to changes in engine load. The IAC valve is used to control engine idle speed, while preventing stalls due changes in engine load. For further information regarding the IAC Valve refer to Fuel Metering Modes of Operation. See: Description and Operation/Fuel Metering/Fuel Metering Modes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 6484 Idle Air Control Motor (IAC): Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the electrical connector from the idle air control valve. 3. Remove the 2 idle air control valve attaching screws. 4. Remove the idle air control valve. 5. Remove the idle air control valve O-ring. INSTALLATION PROCEDURE NOTE: The IAC valve may be damaged if installed with the cone (pintle) extended more than 28 mm (1-1/8 in). Measure the distance that the valve is extended before installing a new valve. The distance from the idle air control valve motor housing to the end of the idle air control valve pintle should be less than 28 mm (1-1/8 in). Manually compressing the pintle until the extension is less than 28 mm (1-1/8 in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Motor (IAC) <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 6485 1. Install the new idle air control O-ring. 2. Install the idle air control valve in the intake manifold. NOTE: Refer to Fastener Notice in Service Precautions. 3. Reinstall the idle air control valve (2) attaching screws. Tighten Tighten the idle air control valve attaching screws to 3.0 N.m (27 lb in). 4. Connect the electrical connector to the idle air control valve. 5. The PCM will reset the idle air control valve whenever the ignition switch is turned ON, then OFF. Turn the ignition switch ON, then OFF. 6. Start the engine and allow the engine to reach operating temperature. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Plenum > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Component Locations Oil Pressure Switch (For Fuel Pump): Component Locations Engine Oil Pressure Indicator Switch (LA1) Front of the engine, above the starter. RPO LA1: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Engine Oil Pressure Indicator Switch (L36) Near generator. RPO L36: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Component Locations > Page 6493 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Component Locations > Page 6494 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 6495 Oil Pressure Switch (For Fuel Pump): Description and Operation Engine Oil Pressure Switch The PCM monitors the engine oil pressure switch (1) signal to determine if the engine oil pressure is OK. If the PCM determines that a low oil pressure condition exists, the PCM will communicate the information over the Class II circuit to the P cluster and it will illuminate the indicator lamp or initiate a message. The low oil pressure message may not appear if other messages are being commanded, such as the rear deck lid, driver or passenger doors ajar. Ensure that all doors and compartment lids are completely closed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6501 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6502 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6503 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6504 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6505 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6506 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6507 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6508 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6509 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6510 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6511 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6512 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6513 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6514 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6515 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6516 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6517 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6518 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6519 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6520 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6521 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6522 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6523 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6524 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6525 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6526 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 6527 Fuel Pump Relay: Service and Repair REMOVAL PROCEDURE 1. Turn the ignition OFF. 2. Remove the under hood electrical center cover. 3. Remove the fuel pump relay. INSTALLATION PROCEDURE 1. Install the fuel pump relay. 2. Install the under hood electrical center cover. 3. Turn the ignition ON. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations LF of the engine compartment, in the air cleaner duct. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions Mass Air Flow (MAF) Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6534 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6535 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6536 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6537 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6538 Mass Air Flow (MAF) Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6539 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6540 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6541 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6542 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6543 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6544 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6545 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6546 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6547 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6548 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6549 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6550 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6551 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6552 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6553 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6554 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6555 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6556 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6557 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6558 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6559 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6560 Mass Air Flow (MAF) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6561 Mass Air Flow (MAF) Sensor: Electrical Diagrams Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 6562 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Page 6563 Mass Air Flow (MAF) Sensor: Description and Operation The Mass Air Flow (MAF) sensor measures the amount of air which passes through it. The PCM uses this information to determine the operating condition of the engine, to control fuel delivery. A large quantity of air indicates acceleration, while a small quantity indicates deceleration or idle. The scan tool reads the MAF value and displays it in grams per second (gm/s). At idle, it should read between 4 gm/s to 6 gm/s on a fully warmed up engine. Values should change rather quickly on acceleration, but values should remain fairly stable at any given RPM. A failure in the MAF sensor or circuit should set DTC P0101 Mass Air Flow (MAF) Sensor Performance, DTC P0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency, or DTC P0103 Mass Air Flow (MAF) Sensor Circuit High Frequency The MAF sensor is attached to the front (air inlet side) of the throttle body and is used to measure the amount of air entering the engine. The PCM uses this information to determine the operating condition of the engine and to control fuel delivery. For further information, refer to Information Sensors/Switches Description. See: Computers and Control Systems/Description and Operation/Information Sensors/Switches Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Diagrams > Page 6564 Mass Air Flow (MAF) Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the MAF sensor (1) electrical connector. 4. Remove the air inlet duct from the MAF sensor and the throttle body. 5. Remove the MAF sensor from the air filter housing. INSTALLATION PROCEDURE 1. Install the MAF sensor to the air filter housing. 2. Install the air inlet duct to the MAF sensor and throttle body. 3. Connect the IAT sensor (1) electrical connector. 4. Connect the MAF sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Component Locations Oil Pressure Switch (For Fuel Pump): Component Locations Engine Oil Pressure Indicator Switch (LA1) Front of the engine, above the starter. RPO LA1: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Engine Oil Pressure Indicator Switch (L36) Near generator. RPO L36: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Component Locations > Page 6569 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Component Locations > Page 6570 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 6571 Oil Pressure Switch (For Fuel Pump): Description and Operation Engine Oil Pressure Switch The PCM monitors the engine oil pressure switch (1) signal to determine if the engine oil pressure is OK. If the PCM determines that a low oil pressure condition exists, the PCM will communicate the information over the Class II circuit to the P cluster and it will illuminate the indicator lamp or initiate a message. The low oil pressure message may not appear if other messages are being commanded, such as the rear deck lid, driver or passenger doors ajar. Ensure that all doors and compartment lids are completely closed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screws 2 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 6575 Throttle Position Sensor: Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 6576 Left Front Of Engine Top of the engine, on the throttle body assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6579 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6580 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6581 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6582 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6583 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6584 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6585 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6586 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6587 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6588 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6589 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6590 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6591 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6592 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6593 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6594 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6595 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6596 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6597 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6598 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6599 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6600 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6601 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6602 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6603 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6604 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6605 Throttle Position Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 6606 Throttle Position Sensor: Description and Operation The Throttle Position (TP) sensor is a potentiometer connected to the throttle shaft on the throttle body. By monitoring the voltage on the signal line, the PCM calculates throttle position. As the throttle valve angle is changed (accelerator pedal moved), the TP sensor signal also changes. At a closed throttle position, the output of the TP sensor is low. As the throttle valve opens, the output increases so that at Wide Open Throttle (WOT), the output voltage should be above 4.0 volts. The PCM calculates fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor may cause intermittent bursts of fuel from an injector and unstable idle because the PCM thinks the throttle is moving. A hard failure in the TP sensor 5.0 volt reference or signal circuits should set either a DTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage. A hard failure with the TP Sensor ground circuit may set DTCs DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage, DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage, DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage, or DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage. Once a DTC is set, the PCM will use an artificial default value based on engine RPM, engine load and mass air flow for throttle position and some vehicle performance will return. A high idle may result when either DTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage, or DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage is set. The PCM can detect intermittent TP sensor faults. DTC P1121 Throttle Position (TP) Sensor Circuit Intermittent High Voltage, or DTC P 1122 Throttle Position (TP) Sensor Circuit Intermittent Low Voltage will set it an intermittent high or low circuit failure is being detected. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 6607 The PCM can also detect a shifted TP sensor (2). The PCM monitors throttle position and compares the actual TP sensor reading to a predicted TP value calculated from engine speed. If the PCM detects an out of range condition, DTC P0121 Throttle Position (TP) Sensor Performance will be set. The non-adjustable TP sensor is mounted on the side of the throttle body opposite the throttle lever. It senses the throttle valve angle and relays that information to the PCM. Knowledge of the throttle angle is needed by the PCM to generate the required injector control signals (pulse). For further information, Refer to Information Sensors/Switches Description. See: Computers and Control Systems/Description and Operation/Information Sensors/Switches Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 6608 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the TP sensor electrical connector. 3. Remove the 2 TP sensor attaching screws. 4. Remove the TP sensor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 6609 5. Remove the TP sensor O-ring. INSTALLATION PROCEDURE 1. Install the TP sensor O-ring. 2. With the throttle valve in the normal closed idle position, install the TP sensor on the throttle body assembly. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 6610 3. Reinstall the 2 TP sensor attaching screws, using a thread-locking compound on the screws. Loctite (R) 262, GM P/N 1052624, or equivalent should be used. Tighten Tighten the TP sensor attaching screws to 2.0 N.m (18 lb in). 4. Connect the TP sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications Throttle Body: Specifications Exhaust Gas Recirculation Valve to Throttle Body Adapter Bolts 30 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 6614 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 6615 Throttle Body: Description and Operation Throttle Body Unit The throttle body has a throttle plate to control the amount of air delivered to the engine. The TP sensor (2), and IAC sensor (1) are also mounted on the throttle body. Vacuum ports located behind the throttle plate provide the vacuum signals needed by various components. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 6616 Throttle Body: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Drain coolant. Refer to Draining and Filling Cooling System in Cooling System. 3. Disconnect the IAT sensor electrical connector. 4. Disconnect the breather tube from the air intake tube. 5. Remove the air intake tube. 6. Disconnect the IAC valve electrical connector. 7. Disconnect the TP sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 6617 8. Disconnect the accelerator controls cable from the throttle lever and accelerator cable bracket. 9. If applicable disconnect the cruise control cable from the throttle lever and accelerator bracket. 10. Remove the accelerator control cable bracket. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 6618 11. Disconnect the throttle body coolant bypass hoses. 12. Disconnect the heater pipe nut at the throttle body. 13. Remove the nuts and bolts holding the throttle body to the intake manifold. 14. Remove the throttle body assembly. INSTALLATION PROCEDURE NOTE: Do Not use solvent of any type when cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as damage to the gasket surfaces and throttle body assembly may result. Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as sharp tools may damage the gasket surfaces. 1. Clean the gasket surface on the intake manifold and the throttle body assembly. 2. Reinstall a new gasket, if necessary. 3. Reinstall the throttle body assembly. NOTE: Refer to Fastener Notice in Service Precautions. 4. Reinstall the throttle body retaining nuts and bolts. Tighten Tighten the throttle body retaining nuts and bolts to 28 N.m (21 lb ft). 5. Connect the throttle body coolant bypass hoses. 6. Connect the heater pipe nut at the throttle body. 7. Connect the IAC valve electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 6619 8. Connect the TP sensor electrical connector. 9. Install the accelerator controls cable bracket. 10. If applicable connect the cruise control cable to the throttle lever and accelerator cable bracket. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 6620 11. Connect the accelerator controls cable to the throttle lever and accelerator cable bracket. 12. Install the air intake tube. 13. Connect the IAT sensor electrical connector. 14. Connect the breather tube into the air intake tube. 15. Refill the coolant. IMPORTANT: The throttle should operate freely without binding between full closed and wide open throttle. 16. Inspect for complete throttle opening and closing positions by operating the accelerator pedal. Also check for poor carpet fit under the accelerator pedal. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Controls Cable Replacement Throttle Cable/Linkage: Service and Repair Accelerator Controls Cable Replacement Accelerator Controls Cable Replacement REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the left instrument panel sound insulator. 3. Disconnect the accelerator cable (5) from the accelerator pedal (1). 4. Squeeze the accelerator cable cover tangs and push the accelerator cable through the bulkhead. 5. Remove the accelerator cable shield, if equipped. 6. Disconnect the accelerator cable from the retaining clip. 7. Disconnect the accelerator cable from the throttle body lever. 8. Disconnect the accelerator cable from the accelerator cable bracket. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Controls Cable Replacement > Page 6625 9. Remove the accelerator cable from vehicle noting cable routing. INSTALLATION NOTE: Do not route flexible components (hoses, wires, conduits, etc.) within 50 mm (2 in) of moving parts unless flexible components can be securely fastened. This is necessary in order to prevent possible interference and damage to the component. 1. Install accelerator cable into car using routing noted during removal 2. Install the snap retainer through the bulkhead. 3. Connect the accelerator cable (5) in the slot in the accelerator pedal lever (1). 4. Seat the snap retainer in the accelerator pedal lever. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Controls Cable Replacement > Page 6626 5. Connect the accelerator cable to the throttle body lever. 6. Connect the accelerator cable to the accelerator cable bracket. 7. Connect the accelerator cable into the retaining clip. 8. Reinstall the accelerator cable shield, if equipped. 9. Inspect and check for complete throttle opening and closing positions by operating the accelerator pedal. Also check for poor carpet fit under the accelerator pedal. 10. Inspect the throttle should operate freely, without binding, between full closed and wide open throttle. 11. Reinstall the left instrument panel sound insulator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Controls Cable Replacement > Page 6627 Throttle Cable/Linkage: Service and Repair Accelerator Controls Cable Bracket Replacement REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the accelerator cable cross slug from throttle body slot. 3. Depress the tangs and remove the accelerator cable from accelerator cable bracket. 4. If applicable disconnect the cruse control cable from the throttle lever and accelerator bracket. 5. Remove the nuts and bolts holding the accelerator cable bracket to the throttle body. 6. Remove the accelerator cable bracket. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Controls Cable Replacement > Page 6628 1. Install the accelerator cable bracket to throttle body. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the nuts and bolts. Tighten ^ Tighten the nuts to 10 N.m (88 lb in). ^ Tighten the bolts to 13 N.m (115 lb in). 3. Connect the accelerator cable into accelerator cable bracket. 4. Connect the accelerator cable cross slug into throttle body slots. 5. If applicable connect the cruise control cable to the throttle lever and accelerator cable bracket. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screws 2 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 6632 Throttle Position Sensor: Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 6633 Left Front Of Engine Top of the engine, on the throttle body assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6636 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6637 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6638 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6639 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6640 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6641 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6642 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6643 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6644 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6645 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6646 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6647 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6648 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6649 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6650 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6651 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6652 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6653 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6654 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6655 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6656 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6657 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6658 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6659 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6660 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6661 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6662 Throttle Position Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 6663 Throttle Position Sensor: Description and Operation The Throttle Position (TP) sensor is a potentiometer connected to the throttle shaft on the throttle body. By monitoring the voltage on the signal line, the PCM calculates throttle position. As the throttle valve angle is changed (accelerator pedal moved), the TP sensor signal also changes. At a closed throttle position, the output of the TP sensor is low. As the throttle valve opens, the output increases so that at Wide Open Throttle (WOT), the output voltage should be above 4.0 volts. The PCM calculates fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor may cause intermittent bursts of fuel from an injector and unstable idle because the PCM thinks the throttle is moving. A hard failure in the TP sensor 5.0 volt reference or signal circuits should set either a DTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage. A hard failure with the TP Sensor ground circuit may set DTCs DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage, DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage, DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage, or DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage. Once a DTC is set, the PCM will use an artificial default value based on engine RPM, engine load and mass air flow for throttle position and some vehicle performance will return. A high idle may result when either DTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage, or DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage is set. The PCM can detect intermittent TP sensor faults. DTC P1121 Throttle Position (TP) Sensor Circuit Intermittent High Voltage, or DTC P 1122 Throttle Position (TP) Sensor Circuit Intermittent Low Voltage will set it an intermittent high or low circuit failure is being detected. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 6664 The PCM can also detect a shifted TP sensor (2). The PCM monitors throttle position and compares the actual TP sensor reading to a predicted TP value calculated from engine speed. If the PCM detects an out of range condition, DTC P0121 Throttle Position (TP) Sensor Performance will be set. The non-adjustable TP sensor is mounted on the side of the throttle body opposite the throttle lever. It senses the throttle valve angle and relays that information to the PCM. Knowledge of the throttle angle is needed by the PCM to generate the required injector control signals (pulse). For further information, Refer to Information Sensors/Switches Description. See: Computers and Control Systems/Description and Operation/Information Sensors/Switches Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 6665 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the TP sensor electrical connector. 3. Remove the 2 TP sensor attaching screws. 4. Remove the TP sensor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 6666 5. Remove the TP sensor O-ring. INSTALLATION PROCEDURE 1. Install the TP sensor O-ring. 2. With the throttle valve in the normal closed idle position, install the TP sensor on the throttle body assembly. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 6667 3. Reinstall the 2 TP sensor attaching screws, using a thread-locking compound on the screws. Loctite (R) 262, GM P/N 1052624, or equivalent should be used. Tighten Tighten the TP sensor attaching screws to 2.0 N.m (18 lb in). 4. Connect the TP sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 89 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations RH side of the engine, below the intake plenum. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 6674 Camshaft Position Sensor: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 6675 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6678 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6679 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6680 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6681 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6682 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6683 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6684 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6685 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6686 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6687 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6688 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6689 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6690 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6691 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6692 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6693 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6694 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6695 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6696 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6697 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6698 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6699 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6700 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6701 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6702 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6703 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6704 Camshaft Position Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position (CMP) Sensor and Cam Signal Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor and Cam Signal The camshaft position sensor sends a cam signal to the PCM which uses it as a sync pulse to trigger the injectors in proper sequence. The PCM uses the CAM signal to indicate the position of the #1 piston during its intake stroke. This allows the PCM to calculate true Sequential Fuel Injection (SFI) mode of operation. If the PCM detects an incorrect CAM signal while the engine is running, DTC P0341 Camshaft Position (CMP) Sensor Performance will set. If the CAM signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection mode based on the last fuel injection pulse, and the engine will continue to run. The engine can be restarted and will run in the calculated sequential mode as long as the fault is present with a 1 in 6 chance of injector sequence being correct. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position (CMP) Sensor and Cam Signal > Page 6707 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The camshaft position sensor is located on the timing cover behind the water pump near the camshaft sprocket. As the camshaft sprocket turns, a magnet in it activates the Hall-effect switch in the camshaft position sensor. When the Hall-effect switch is activated, it grounds the signal line to the PCM, pulling the camshaft position sensor signal circuit's applied voltage low. This is interpreted as a CAM signal. The CAM signal is created as piston #1 is on the intake stroke. If the correct CAM signal is not received by the PCM, DTC P0341 will be set. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 6708 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the serpentine drive belt. 3. Loosen the power steering pump to gain access to the CMP. 4. Disconnect the sensor electrical connector. 5. Remove the attaching bolt. 6. Remove the sensor. 7. Inspect the sensor for wear, cracks or leakage if the sensor is not being replaced. INSTALLATION PROCEDURE 1. Lubricate the O-ring with clean engine oil and replace if damaged. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the camshaft position sensor. Tighten Tighten the retaining bolt to 10 N.m (88 lb in). 3. Connect the sensor electrical connector. 4. Install the power steering pump. 5. Reinstall the serpentine drive belt. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt Front Cover 89 in.lb Crankshaft Position Sensor Stud Side of Engine Block 98 in.lb Crankshaft Position Sensor Wiring Bracket Bolt 37 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 6714 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 6715 Locations View Crankshaft Position (24X) Sensor RH side of the engine, at the end of the crankshaft, behind the harmonic balancer. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 6716 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6719 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6720 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6721 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6722 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6723 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6724 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6726 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6727 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6728 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6729 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6730 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6731 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6732 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6733 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6734 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6735 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6736 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6737 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6738 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6739 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6740 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6741 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6742 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6743 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6744 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6745 Crankshaft Position Sensor (24X) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 7X Crankshaft Position (CKP) Sensor Crankshaft Position Sensor: Description and Operation 7X Crankshaft Position (CKP) Sensor The 7X crankshaft position sensor provides a signal used by the ignition control module. The ignition control module also uses the 7X crankshaft position sensor to generate 3X reference pulses which the PCM uses to calculate RPM and crankshaft position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 7X Crankshaft Position (CKP) Sensor > Page 6748 Crankshaft Position Sensor: Description and Operation 24X Crankshaft Position (CKP) Sensor 24X Crankshaft Position (CKP) Sensor The 24X crankshaft position (CKP) sensor (1) is used to improve idle spark control at engine speeds up to approximately 1600 RPM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure The Crankshaft Position System Variation compensating values are stored in the PCM non-volatile memory after a learn procedure has been performed. If the actual Crankshaft Position System Variation is not within the Crankshaft Position System Variation compensating values stored in the PCM, DTC P0300 may set. Refer to Diagnostic Aids for DTC P0300. The Crankshaft Position System Variation Learn Procedure should be performed if any of the following conditions are true: ^DTC P1336 is set. ^ The PCM has been replaced. ^ The engine has been replaced. ^ The crankshaft has been replaced. ^ The crankshaft harmonic balancer has been replaced. ^ The crankshaft position sensor has been replaced. Important: The scan tool Crankshaft Position System Variation Learn function will be inhibited if engine coolant temperature is less than 70°C (158°F). Allow the engine to warm to at least 70°C (158°F) before attempting the Crankshaft Position System Variation Learn Procedure. The scan tool Crankshaft Position System Variation Learn function will be inhibited if any Powertrain DTCs other than DTC P1336 are set before or during the Crankshaft Position System Variation Learn Procedure. Diagnose and repair any DTCs if set. Refer to applicable DTCs. The Crankshaft Position System Variation Learn function will be inhibited if the PCM detects a malfunction involving the camshaft position signal circuit, the 3X reference circuit, or the 24X reference circuit. If a malfunction has been indicated, refer to the following list to diagnose the system or sensor. ^ DTC P0336 Crankshaft Position (CKP) Sensor Circuit. ^ DTC P0341 Camshaft Position (CMP) Sensor Performance. ^ DTC P1374 Crankshaft Position (CKP) High to Low Resolution Frequency Correlation. The scan tool Crankshaft Position System Variation Learn function will not be enabled until engine coolant temperature reaches 70°C (158°F) Selecting the crankshaft position system variation learn procedure on the scan tool will command the PCM to enable CKP system variation learn fuel cutoff and allow the crankshaft position system variation compensating values to be stored in the PCM. The PCM must detect an engine speed of 5150 RPM (CKP system variation learn fuel cutoff) during the Crankshaft Position System Variation Learn Procedure to store the crankshaft position system variation compensating values and complete the procedure. Important: Block the drive wheels when performing the Crankshaft Position System Variation Learning Procedure in order to prevent personal injury. Set the vehicle parking brake when instructed by the scan tool. Quickly increase the accelerator pedal until wide open throttle is reached and hold. During the learn procedure the PCM will automatically control injector operation, when the RPM has reached a certain RPM the PCM will stop the fuel injectors from pulsing until the learn procedure is finished. When the PCM has learned the crankshaft variation the fuel injectors will return to normal operation and the engine will begin to accelerate again. Release the throttle when the engine reaches the second fuel cut off. Leaving the throttle open during the fuel cut off learn procedure will allow the engine to decel at an even rate. 1. Block the drive wheels. 2. Ensure the hood is closed. 3. Start the engine and allow engine coolant temperature to reach at least 70°C (158°F) 4. Turn OFF the ignition. 5. Select and enable the Crankshaft Position System Variation Learn Procedure with the scan tool. 6. Set the parking brake when instructed by the scan tool. 7. Start the vehicle. 8. Apply and hold the service brake pedal firmly. 9. Ensure the transaxle is in park. 10. Steadily increase the accelerator pedal until the fuel cutoff is reached at 5150 RPM and hold. Release the accelerator pedal after the second fuel cutoff has been reached. 11. The crankshaft position system variation compensating values are learned when the RPM decreases back to idle. If the procedure terminates. 12. Observe DTC status for DTC P1336. 13. If the scan tool indicates that DTC P1336 ran and passed, the Crankshaft Position System Variation Learn Procedure is complete. If the scan tool indicates DTC P1336 failed or not run, determine if other DTCs have set. If DTCs other than P1336 are not set, repeat the Crankshaft Position System Variation Learn Procedure as necessary. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 6751 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement (7X) REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Crank steering wheel fully to the left. 3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting. 4. Remove the right tire and wheel. 5. Disconnect the sensor electrical connector. 6. Remove the attaching bolt/screw. 7. Remove the sensor from engine. 8, Inspect for wear, cracks, or leakage if the sensor is not being replaced. INSTALLATION PROCEDURE 1. Lubricate the O-ring with clean engine oil before installation and replace if damaged. 2. Install the sensor to the block. 3. Reinstall the sensor attaching bolt. Tighten Tighten the bolt to 11 N.m (97 lb in). 4. Connect the sensor electrical connector. 5. Install the right tire and wheel. 6. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 6752 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement (24X) REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the serpentine drive belt from crankshaft pulley. 3. Raise the vehicle on hoist. Refer to Lifting and Jacking the Vehicle in General Information 4. Remove the crankshaft harmonic balancer. 5. Note the routing of sensor harness before removal. 6. Remove the harness retaining clip with bolt (1). 7. Disconnect the sensor electrical connector. 8, Remove the sensor bolts (4). 9. Remove the sensor. INSTALLATION PROCEDURE 1. Install the 24X crankshaft position sensor with bolts (4) and route harness as noted during removal. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the harness retaining clip with bolt (3). Tighten Tighten the bolts to 10 N.m (88 lb in). 3. Connect the sensor electrical connector. 4. Reinstall the balancer on the crankshaft. 5. Lower vehicle. 6. Reinstall the serpentine drive belt. 7. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Locations > Page 6756 Ignition Cable: Service Precautions NOTE: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Locations > Page 6757 Ignition Cable: Service and Repair REMOVAL PROCEDURE 1. Turn the ignition switch to the OFF position. 2. Note the position of the spark plug wire retaining clips. Remove the spark plug wire retaining clips from the engine. NOTE: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged. 3. Note the position of the spark plug wire(s). Remove the spark plug wires (2,4,6) from the front spark plugs by twisting the boot 1/2 turn before removing the spark plug boot(s). 4. Note the position of the spark plug wire(s). Remove the spark plug wires (1,3,5) from the rear spark plugs by twisting the boot 1/2 turn before removing the spark plug boot(s). 5. Remove the spark plug wire retaining clips from the rear of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Locations > Page 6758 6. Remove the spark plug wires from the ignition coils. 7. Remove the spark plug wires from the engine. 8. If replacing the spark plug wires, transfer any of the following: ^ Boot heat shields ^ Spark plug wire conduit ^ Spark plug wire retaining clips INSTALLATION PROCEDURE 1. Position the spark plug wire(s) to the engine. 2. Install the spark plug wires to the ignition coils in the proper position. 3. Install the spark plug wires (1,3,5) to the rear spark plugs. 4. Install the spark plug wire retaining clips from the rear of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Locations > Page 6759 5. Install the spark plug wire (2,4,6) to the front spark plugs. 6. Install the spark plug wire retaining clips to the front of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications Ignition Coil: Specifications Ignition Coil to Ignition Control Module Screws 4.5 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 6763 Ignition Coil: Description and Operation Three twin-tower ignition coils are individually mounted to the ignition control module. Each coil provides spark for two plugs simultaneously (waste spark distribution). Each coil is serviced separately. Two terminals connect each coil pack to the module. Each coil is provided a fused ignition feed. The other terminal at each coil is individually connected to the module, which will energize one coil at a time by completing and interrupting the primary circuit ground path to each coil at the proper time. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 6764 Ignition Coil: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition 2. Note position of spark plug wires for installation and disconnect the spark plug wires from ignition coils (2). 3. Remove the 2 screws (1) securing ignition coil (2) to ignition control module (3). 4. Remove the ignition coil (2). INSTALLATION PROCEDURE 1. Install the ignition coil (2) on the ignition control module (3). NOTE: Refer to Fastener Notice in Service Precautions. 2. Reinstall the 2 attaching screws (1). Tighten Tighten the screws to 4.5 N.m (40 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 6765 3. Connect the spark plug wires as noted during removal. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Specifications Ignition Control Module: Specifications Ignition Coil to Ignition Control Module Screws 4.5 Nm Ignition Controle Module Bracket to Engine Studs and Nuts 25 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Component Locations > Page 6771 Ignition Control Module: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Component Locations > Page 6772 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Ignition Control Module C1 Ignition Control Module (ICM), C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Ignition Control Module C1 > Page 6775 Ignition Control Module (ICM), C2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Page 6776 Ignition Control Module: Description and Operation Ignition Control (IC) Module The Ignition Control (IC) module performs the following functions: ^ It determines the correct ignition coil firing sequence, based on 7X pulses. This coil sequencing occurs at start-up. After the engine is running, the module determines the sequence, and continues triggering the ignition coils in proper sequence. ^ It sends the 3X crankshaft reference (fuel control) signal to the PCM. The PCM determines engine RPM from this signal. this signal is also used by the PCM to determine crankshaft speed for ignition control (IC) spark advance calculations. The 3X reference signal sent to the PCM by the IC module is an on, off pulse occurring 3 times per crankshaft revolution. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Page 6777 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect all the electrical connectors at the ignition control module. 3. Note position of spark plug wires for installation and disconnect the spark plug wires from ignition coils. 4. Remove the screws securing coil assemblies to ignition control module. 5. Disconnect the coils from ignition control module. 6. Remove the fasteners securing ignition control module assembly to engine. 7. Remove the ignition control module from the module mounting bracket. INSTALLATION PROCEDURE 1. Install the ignition control module on the module mounting bracket. 2. Install the coils to ignition control module. 3. Reinstall the screws through the coils and module into the module mounting bracket. NOTE: Refer to Fastener Notice in Service Precautions. 4. Reinstall the screws. Tighten Tighten the screws to 4-5 N.m (40 lb in). 5. Connect the spark plug wires as noted during removal. 6. Connect the electrical connectors to the ignition control module. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications knock Sensor 19 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Component Locations Knock Sensor: Component Locations Left Front Of Engine Knock Sensor (KS) Bank 1 Lower RR of the engine, below the exhaust manifold. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Component Locations > Page 6783 Knock Sensor: Connector Locations Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Component Locations > Page 6784 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6787 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6788 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6789 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6790 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6791 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6792 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6793 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6794 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6795 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6796 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6797 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6798 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6799 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6800 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6801 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6802 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6803 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6804 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6805 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6806 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6807 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6808 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6809 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6810 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6811 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6812 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6813 Knock Sensor (KS) 1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6814 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > General Information Knock Sensor: Description and Operation General Information The knock sensor detects abnormal vibration (spark knocking) in the engine. The sensor is located on the engine block near the cylinders. The sensor produces an AC output voltage which increases with the severity of the knock. This signal voltage is input to the PCM. The PCM then adjusts the Ignition Control (IC) timing to reduce spark knock. DTC P0325 Knock Sensor (KS) Circuit DTC P0327 Knock Sensor (KS) Circuit are designed to diagnose the PCM, the knock sensor, and related wiring, so problems encountered with the KS system should set a DTC. Refer to Knock Sensor (KS) System Description description of the knock sensor system. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > General Information > Page 6817 Knock Sensor: Description and Operation Operation The knock sensor detects abnormal vibration (spark knocking) in the engine. The knock sensor is mounted in the engine block near the cylinders and produce an AC signal under all engine operating conditions. The PCM contains integrated Knock Sensor (KS) diagnostic circuitry which uses the input signals from the knock sensors to detect engine detonation. This allows the PCM to retard Ignition Control (IC) spark timing based on the amplitude and frequency of the KS signal being received. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > General Information > Page 6818 Knock Sensor: Description and Operation Purpose Knock Sensor (KS) System Description Purpose Varying octane levels in todays gasoline may cause detonation in some engines. Detonation is caused by an uncontrolled explosion (burn) in the combustion chamber. This uncontrolled explosion could produce a flame front opposite that of the normal flame front produced by the spark plug. The rattling sound normally associated with detonation is the result of two or more opposing pressures (flame fronts) colliding within the combustion chamber. Though light detonation is sometimes considered normal, heavy detonation could result in engine damage. To control spark knock, a Knock Sensor (KS) system is used. This system is designed to retard spark timing when spark knock is detected in the engine. The KS system allows the engine to use maximum spark advance for optimal driveability and fuel economy. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > Page 6819 Knock Sensor: Testing and Inspection The PCM calculates an average voltage the knock sensor signal and takes instantaneous signal voltage readings. The PCM uses the instantaneous signal voltage reading to determine the state of the knock sensor circuitry. If the knock sensor system is operating normally, the PCM should monitor instantaneous KS signal voltage readings varying outside a voltage range above and below the calculated average voltage. The following DTCs are used to diagnose the knock sensor system: ^ If the PCM malfunctions in a manner which will not allow proper diagnosis of the KS circuits, DTC P0325 will set. ^ DTC P0327 is designed to diagnose the knock sensor, and related wiring, so problems encountered with the KS system should set a DTC. However, if no DTC was set but the KS system is suspect because detonation was the customer's complaint, use the tables for P0327 to diagnose the Detonation/Spark Knock Symptom. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > Page 6820 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting. 3. Disconnect the knock sensor wiring harness connector from the knock sensor. 4. Remove the knock sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Do Not apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. NOTE: Refer to Fastener Notice in Service Precautions. Knock Sensor (KS) System Deascription Purpose 1. Install the knock sensor into engine block. Tighten Tighten the knock sensor to 19 N.m (14 lb ft). 2. Connect the knock sensor wiring harness connector to the knock sensor. 3. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Specifications Ignition Control Module: Specifications Ignition Coil to Ignition Control Module Screws 4.5 Nm Ignition Controle Module Bracket to Engine Studs and Nuts 25 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Component Locations > Page 6827 Ignition Control Module: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Component Locations > Page 6828 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Ignition Control Module C1 Ignition Control Module (ICM), C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Ignition Control Module C1 > Page 6831 Ignition Control Module (ICM), C2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 6832 Ignition Control Module: Description and Operation Ignition Control (IC) Module The Ignition Control (IC) module performs the following functions: ^ It determines the correct ignition coil firing sequence, based on 7X pulses. This coil sequencing occurs at start-up. After the engine is running, the module determines the sequence, and continues triggering the ignition coils in proper sequence. ^ It sends the 3X crankshaft reference (fuel control) signal to the PCM. The PCM determines engine RPM from this signal. this signal is also used by the PCM to determine crankshaft speed for ignition control (IC) spark advance calculations. The 3X reference signal sent to the PCM by the IC module is an on, off pulse occurring 3 times per crankshaft revolution. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 6833 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect all the electrical connectors at the ignition control module. 3. Note position of spark plug wires for installation and disconnect the spark plug wires from ignition coils. 4. Remove the screws securing coil assemblies to ignition control module. 5. Disconnect the coils from ignition control module. 6. Remove the fasteners securing ignition control module assembly to engine. 7. Remove the ignition control module from the module mounting bracket. INSTALLATION PROCEDURE 1. Install the ignition control module on the module mounting bracket. 2. Install the coils to ignition control module. 3. Reinstall the screws through the coils and module into the module mounting bracket. NOTE: Refer to Fastener Notice in Service Precautions. 4. Reinstall the screws. Tighten Tighten the screws to 4-5 N.m (40 lb in). 5. Connect the spark plug wires as noted during removal. 6. Connect the electrical connectors to the ignition control module. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 89 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations RH side of the engine, below the intake plenum. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 6840 Camshaft Position Sensor: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 6841 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6844 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6845 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6846 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6847 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6848 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6849 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6850 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6851 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6852 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6853 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6854 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6855 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6856 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6857 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6858 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6859 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6860 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6861 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6862 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6863 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6864 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6865 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6866 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6867 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6868 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6869 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6870 Camshaft Position Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position (CMP) Sensor and Cam Signal Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor and Cam Signal The camshaft position sensor sends a cam signal to the PCM which uses it as a sync pulse to trigger the injectors in proper sequence. The PCM uses the CAM signal to indicate the position of the #1 piston during its intake stroke. This allows the PCM to calculate true Sequential Fuel Injection (SFI) mode of operation. If the PCM detects an incorrect CAM signal while the engine is running, DTC P0341 Camshaft Position (CMP) Sensor Performance will set. If the CAM signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection mode based on the last fuel injection pulse, and the engine will continue to run. The engine can be restarted and will run in the calculated sequential mode as long as the fault is present with a 1 in 6 chance of injector sequence being correct. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position (CMP) Sensor and Cam Signal > Page 6873 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The camshaft position sensor is located on the timing cover behind the water pump near the camshaft sprocket. As the camshaft sprocket turns, a magnet in it activates the Hall-effect switch in the camshaft position sensor. When the Hall-effect switch is activated, it grounds the signal line to the PCM, pulling the camshaft position sensor signal circuit's applied voltage low. This is interpreted as a CAM signal. The CAM signal is created as piston #1 is on the intake stroke. If the correct CAM signal is not received by the PCM, DTC P0341 will be set. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 6874 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the serpentine drive belt. 3. Loosen the power steering pump to gain access to the CMP. 4. Disconnect the sensor electrical connector. 5. Remove the attaching bolt. 6. Remove the sensor. 7. Inspect the sensor for wear, cracks or leakage if the sensor is not being replaced. INSTALLATION PROCEDURE 1. Lubricate the O-ring with clean engine oil and replace if damaged. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the camshaft position sensor. Tighten Tighten the retaining bolt to 10 N.m (88 lb in). 3. Connect the sensor electrical connector. 4. Install the power steering pump. 5. Reinstall the serpentine drive belt. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt Front Cover 89 in.lb Crankshaft Position Sensor Stud Side of Engine Block 98 in.lb Crankshaft Position Sensor Wiring Bracket Bolt 37 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 6880 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 6881 Locations View Crankshaft Position (24X) Sensor RH side of the engine, at the end of the crankshaft, behind the harmonic balancer. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 6882 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6885 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6886 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6887 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6888 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6889 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6890 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6891 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6892 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6893 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6894 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6895 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6896 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6897 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6898 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6899 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6900 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6901 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6902 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6903 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6904 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6905 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6906 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6907 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6908 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6909 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6910 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6911 Crankshaft Position Sensor (24X) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 7X Crankshaft Position (CKP) Sensor Crankshaft Position Sensor: Description and Operation 7X Crankshaft Position (CKP) Sensor The 7X crankshaft position sensor provides a signal used by the ignition control module. The ignition control module also uses the 7X crankshaft position sensor to generate 3X reference pulses which the PCM uses to calculate RPM and crankshaft position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 7X Crankshaft Position (CKP) Sensor > Page 6914 Crankshaft Position Sensor: Description and Operation 24X Crankshaft Position (CKP) Sensor 24X Crankshaft Position (CKP) Sensor The 24X crankshaft position (CKP) sensor (1) is used to improve idle spark control at engine speeds up to approximately 1600 RPM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure The Crankshaft Position System Variation compensating values are stored in the PCM non-volatile memory after a learn procedure has been performed. If the actual Crankshaft Position System Variation is not within the Crankshaft Position System Variation compensating values stored in the PCM, DTC P0300 may set. Refer to Diagnostic Aids for DTC P0300. The Crankshaft Position System Variation Learn Procedure should be performed if any of the following conditions are true: ^DTC P1336 is set. ^ The PCM has been replaced. ^ The engine has been replaced. ^ The crankshaft has been replaced. ^ The crankshaft harmonic balancer has been replaced. ^ The crankshaft position sensor has been replaced. Important: The scan tool Crankshaft Position System Variation Learn function will be inhibited if engine coolant temperature is less than 70°C (158°F). Allow the engine to warm to at least 70°C (158°F) before attempting the Crankshaft Position System Variation Learn Procedure. The scan tool Crankshaft Position System Variation Learn function will be inhibited if any Powertrain DTCs other than DTC P1336 are set before or during the Crankshaft Position System Variation Learn Procedure. Diagnose and repair any DTCs if set. Refer to applicable DTCs. The Crankshaft Position System Variation Learn function will be inhibited if the PCM detects a malfunction involving the camshaft position signal circuit, the 3X reference circuit, or the 24X reference circuit. If a malfunction has been indicated, refer to the following list to diagnose the system or sensor. ^ DTC P0336 Crankshaft Position (CKP) Sensor Circuit. ^ DTC P0341 Camshaft Position (CMP) Sensor Performance. ^ DTC P1374 Crankshaft Position (CKP) High to Low Resolution Frequency Correlation. The scan tool Crankshaft Position System Variation Learn function will not be enabled until engine coolant temperature reaches 70°C (158°F) Selecting the crankshaft position system variation learn procedure on the scan tool will command the PCM to enable CKP system variation learn fuel cutoff and allow the crankshaft position system variation compensating values to be stored in the PCM. The PCM must detect an engine speed of 5150 RPM (CKP system variation learn fuel cutoff) during the Crankshaft Position System Variation Learn Procedure to store the crankshaft position system variation compensating values and complete the procedure. Important: Block the drive wheels when performing the Crankshaft Position System Variation Learning Procedure in order to prevent personal injury. Set the vehicle parking brake when instructed by the scan tool. Quickly increase the accelerator pedal until wide open throttle is reached and hold. During the learn procedure the PCM will automatically control injector operation, when the RPM has reached a certain RPM the PCM will stop the fuel injectors from pulsing until the learn procedure is finished. When the PCM has learned the crankshaft variation the fuel injectors will return to normal operation and the engine will begin to accelerate again. Release the throttle when the engine reaches the second fuel cut off. Leaving the throttle open during the fuel cut off learn procedure will allow the engine to decel at an even rate. 1. Block the drive wheels. 2. Ensure the hood is closed. 3. Start the engine and allow engine coolant temperature to reach at least 70°C (158°F) 4. Turn OFF the ignition. 5. Select and enable the Crankshaft Position System Variation Learn Procedure with the scan tool. 6. Set the parking brake when instructed by the scan tool. 7. Start the vehicle. 8. Apply and hold the service brake pedal firmly. 9. Ensure the transaxle is in park. 10. Steadily increase the accelerator pedal until the fuel cutoff is reached at 5150 RPM and hold. Release the accelerator pedal after the second fuel cutoff has been reached. 11. The crankshaft position system variation compensating values are learned when the RPM decreases back to idle. If the procedure terminates. 12. Observe DTC status for DTC P1336. 13. If the scan tool indicates that DTC P1336 ran and passed, the Crankshaft Position System Variation Learn Procedure is complete. If the scan tool indicates DTC P1336 failed or not run, determine if other DTCs have set. If DTCs other than P1336 are not set, repeat the Crankshaft Position System Variation Learn Procedure as necessary. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 6917 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement (7X) REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Crank steering wheel fully to the left. 3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting. 4. Remove the right tire and wheel. 5. Disconnect the sensor electrical connector. 6. Remove the attaching bolt/screw. 7. Remove the sensor from engine. 8, Inspect for wear, cracks, or leakage if the sensor is not being replaced. INSTALLATION PROCEDURE 1. Lubricate the O-ring with clean engine oil before installation and replace if damaged. 2. Install the sensor to the block. 3. Reinstall the sensor attaching bolt. Tighten Tighten the bolt to 11 N.m (97 lb in). 4. Connect the sensor electrical connector. 5. Install the right tire and wheel. 6. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 6918 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement (24X) REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the serpentine drive belt from crankshaft pulley. 3. Raise the vehicle on hoist. Refer to Lifting and Jacking the Vehicle in General Information 4. Remove the crankshaft harmonic balancer. 5. Note the routing of sensor harness before removal. 6. Remove the harness retaining clip with bolt (1). 7. Disconnect the sensor electrical connector. 8, Remove the sensor bolts (4). 9. Remove the sensor. INSTALLATION PROCEDURE 1. Install the 24X crankshaft position sensor with bolts (4) and route harness as noted during removal. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the harness retaining clip with bolt (3). Tighten Tighten the bolts to 10 N.m (88 lb in). 3. Connect the sensor electrical connector. 4. Reinstall the balancer on the crankshaft. 5. Lower vehicle. 6. Reinstall the serpentine drive belt. 7. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Switch Lock Cylinder - Dash Mounted Ignition Switch Lock Cylinder: Service and Repair Ignition Switch Lock Cylinder - Dash Mounted IGNITION SWITCH LOCK CYLINDER REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the body control module (BCM) theft deterrent relearn procedure whenever you replace the ignition switch lock cylinder. See: Computers and Control Systems/Body Control Module/Service and Repair/Procedures/Body Control Module (BCM) Programming/RPO Configuration 1. Disconnect the negative battery cable. 2. Remove the instrument panel (I/P) cluster trim plate. 3. Insert the key and turn the ignition lock cylinder to the ON/RUN position. 4. Using a small curved tool or an L-shaped hex wrench, depress and hold the detent on the ignition lock cylinder. Access the detent by placing the tool through the I/P opening to the right of the ignition switch. If you cannot locate the detent with the tool, lower the ignition switch away from the I/P. Refer to Ignition Switch Replacement. 5. Using the key as an aid, pull to remove the lock cylinder from the switch. 6. Remove the key from the lock cylinder. 7. If the cylinder does not rotate or is seized, follow the procedure in the ignition switch replacement. Refer to Ignition Switch Replacement. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Switch Lock Cylinder - Dash Mounted > Page 6924 1. Code the ignition lock cylinder, if necessary. Refer to Key and Lock Cylinder Coding. 2. Insert the key and turn the lock cylinder to the ON/RUN position. 3. Position the lock cylinder to the ignition switch. Press the cylinder into place. If you turned the key slightly while removing the lock cylinder, you may have to align the white colored ignition switch rotor (1) with the lock cylinder (2). You can rotate the ignition switch rotor (1) with your finger. 4. Turn the key to the OFF position and remove the key. 5. Install the I/P cluster trim plate. 6. Connect the negative battery cable. 7. If you installed a new lock cylinder, perform the BCM theft deterrent relearn procedure. See: Computers and Control Systems/Body Control Module/Service and Repair/Procedures/Body Control Module (BCM) Programming/RPO Configuration Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Switch Lock Cylinder - Dash Mounted > Page 6925 Ignition Switch Lock Cylinder: Service and Repair Programming/Learn Procedures Programming Replacement Lock Cylinder, BCM or PCM IMPORTANT: Reprogram the body control module (BCM) with the proper RPO configurations before you perform the learn procedures. When you replace the BCM, the module will learn Passlock Sensor Data Code immediately. However, the existing PCM must learn the new fuel continue password. When you replace a PCM, after programming, these modules will learn the incoming fuel continue password immediately upon receipt of a password message. Once a password message is received, and a password is learned, perform the learn procedure again if you want to change this password. A PCM which was previously installed in another vehicle will have learned the other vehicle's fuel continue password, and will require a learn procedure after programming in order to learn the current vehicle's password. 10 Minute Re-Learn Procedure Use this procedure after replacing any of the following components: 1. Lock Cylinders/Passlock Sensors 2. BCM 3. PCM Tech 2 Programming Procedure Use the following procedures in order to program the BCM with the Tech 2 equipment. 1. Connect the Tech 2 Diagnostic tool. 2. Select Request Information under Service Programming. 3. Disconnect the Tech 2 from the vehicle and connect it to a Techline Terminal. 4. On the Techline Terminal, select Theft Module Re-Learn under Service Programming. 5. Disconnect the Tech 2 from the Techline Terminal and connect the Tech 2 to the vehicle. 6. Turn ON the ignition, with the engine OFF. 7. Select VTD Re-Learn under Service Programming. 8. At this point you may disconnect the Tech 2, the Tech 2 is no longer required. 9. Observe the Security telltale, after approximately 10 minutes the telltale will turn OFF. The vehicle is now ready to relearn the Passlock Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. 10. Turn OFF the ignition, and wait 5 seconds. 11. Start the engine. (The vehicle has now learned keys). 12. Using a scan tool, clear any DTCs. 30 Minute Re-Learn Procedure Use this procedure after replacing lock cylinders, Passlock Module/BCM or the PCM (if necessary - see note above). 1. Turn ON the ignition, with the engine OFF. 2. Attempt to start the engine, then release the key to ON (The vehicle will not start). 3. Observe the Security telltale, after approximately 10 minutes the telltale will turn OFF. 4. Turn OFF the ignition, and wait 5 seconds. 5. Repeat steps 1-4 two more times, for a total of 3 cycles and 30 minutes. The vehicle is now ready to relearn the Passlock Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. IMPORTANT: The vehicle learns the Passlock Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. You must turn the ignition OFF before attempting to start the vehicle. 6. Start the engine. (The vehicle has now learned the Passlock Sensor Data Code and/or password.) 7. Using a scan tool, clear any DTCs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications knock Sensor 19 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations Knock Sensor: Component Locations Left Front Of Engine Knock Sensor (KS) Bank 1 Lower RR of the engine, below the exhaust manifold. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations > Page 6931 Knock Sensor: Connector Locations Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations > Page 6932 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6935 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6936 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6937 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6938 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6939 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6940 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6941 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6942 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6943 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6944 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6945 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6946 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6947 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6948 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6949 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6950 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6951 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6952 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6953 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6954 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6955 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6956 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6957 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6958 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6959 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6960 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6961 Knock Sensor (KS) 1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6962 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > General Information Knock Sensor: Description and Operation General Information The knock sensor detects abnormal vibration (spark knocking) in the engine. The sensor is located on the engine block near the cylinders. The sensor produces an AC output voltage which increases with the severity of the knock. This signal voltage is input to the PCM. The PCM then adjusts the Ignition Control (IC) timing to reduce spark knock. DTC P0325 Knock Sensor (KS) Circuit DTC P0327 Knock Sensor (KS) Circuit are designed to diagnose the PCM, the knock sensor, and related wiring, so problems encountered with the KS system should set a DTC. Refer to Knock Sensor (KS) System Description description of the knock sensor system. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > General Information > Page 6965 Knock Sensor: Description and Operation Operation The knock sensor detects abnormal vibration (spark knocking) in the engine. The knock sensor is mounted in the engine block near the cylinders and produce an AC signal under all engine operating conditions. The PCM contains integrated Knock Sensor (KS) diagnostic circuitry which uses the input signals from the knock sensors to detect engine detonation. This allows the PCM to retard Ignition Control (IC) spark timing based on the amplitude and frequency of the KS signal being received. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > General Information > Page 6966 Knock Sensor: Description and Operation Purpose Knock Sensor (KS) System Description Purpose Varying octane levels in todays gasoline may cause detonation in some engines. Detonation is caused by an uncontrolled explosion (burn) in the combustion chamber. This uncontrolled explosion could produce a flame front opposite that of the normal flame front produced by the spark plug. The rattling sound normally associated with detonation is the result of two or more opposing pressures (flame fronts) colliding within the combustion chamber. Though light detonation is sometimes considered normal, heavy detonation could result in engine damage. To control spark knock, a Knock Sensor (KS) system is used. This system is designed to retard spark timing when spark knock is detected in the engine. The KS system allows the engine to use maximum spark advance for optimal driveability and fuel economy. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Page 6967 Knock Sensor: Testing and Inspection The PCM calculates an average voltage the knock sensor signal and takes instantaneous signal voltage readings. The PCM uses the instantaneous signal voltage reading to determine the state of the knock sensor circuitry. If the knock sensor system is operating normally, the PCM should monitor instantaneous KS signal voltage readings varying outside a voltage range above and below the calculated average voltage. The following DTCs are used to diagnose the knock sensor system: ^ If the PCM malfunctions in a manner which will not allow proper diagnosis of the KS circuits, DTC P0325 will set. ^ DTC P0327 is designed to diagnose the knock sensor, and related wiring, so problems encountered with the KS system should set a DTC. However, if no DTC was set but the KS system is suspect because detonation was the customer's complaint, use the tables for P0327 to diagnose the Detonation/Spark Knock Symptom. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Page 6968 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting. 3. Disconnect the knock sensor wiring harness connector from the knock sensor. 4. Remove the knock sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Do Not apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. NOTE: Refer to Fastener Notice in Service Precautions. Knock Sensor (KS) System Deascription Purpose 1. Install the knock sensor into engine block. Tighten Tighten the knock sensor to 19 N.m (14 lb ft). 2. Connect the knock sensor wiring harness connector to the knock sensor. 3. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug Usage Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service Precautions > Spark Plug Service Precautions Spark Plug: Service Precautions Spark Plug Service Precautions NOTE: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged. NOTE: Observe the following service precautions: ^ Allow the engine to cool before removing the spark plugs. Attempting to remove spark plugs from a hot engine can cause the spark plugs to seize. This can damage the cylinder head threads. ^ Clean the spark plug recess area before removing the spark plug. Failure to do so can result in engine damage due to dirt or foreign material entering the cylinder head, or in contamination of the cylinder head threads. Contaminated threads may prevent proper seating of the new spark plug. ^ Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the vehicle. Installing spark plugs of another type can severely damage the engine. NOTE: ^ It is important to check the gap of all new and reconditioned spark plugs before installation. Pre-set gaps may have changed during handling. Use a round wire feeler gauge to be sure of an accurate check, particularly on used plugs. Installing plugs with the wrong gap can cause poor engine performance and may even damage the engine. ^ Be sure plug threads smoothly into cylinder head and is fully seated. Use a thread chaser if necessary to clean threads in cylinder head. Cross-threading or failing to fully seat spark plug can cause overheating of plug, exhaust blow-by, or thread damage. Follow the recommended torque specifications carefully. Over or under-tightening can also cause severe damage to engine or spark plug. NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service Precautions > Spark Plug Service Precautions > Page 6974 Spark Plug: Service Precautions Platinum Tip Spark Plug Maintenance Information Platinum Tip Spark Plug Maintenance Information for all 95-02 Models Equipped with Platinum Tip Spark Plugs The following information was originally sent to all General Motors dealers as a DCS message on October 14, 1999. Recommendation / Instructions: It has come to our attention that some GM dealers sell a customer service to remove platinum tipped spark plugs and clean the threads at regular intervals to prevent the seizure of the spark plugs in the cylinder heads at high mileage. Platinum tipped spark plugs are designed to operate under normal vehicle operating conditions for up to 100,000 miles (160,000 kms) without periodic maintenance. When no engine performance concerns are present, platinum tipped spark plugs should not be removed for periodic inspection and cleaning of threads, doing so would compromise the spark plugs ability to withstand their corrosive environment. The threaded area, although not sealed, serves as a protective environment against most harmful elements. Removing and cleaning spark plugs will introduce metallic debris and brush scrapings into the thread area which may further the corrosion process. Chromate coated spark plugs should not be wire brushed or handled in any way once they are put in service. Chromium topcoats form a protective oxide on spark plugs that is not effective if scratched. Both coated and uncoated spark plugs will have the best chance of surviving a corrosive environment if they are left in position. Attempts to maintain spark plugs by removing them and cleaning the threads can actually create the corrosive condition that the procedure was intended to prevent. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service Precautions > Page 6975 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ........................................................ AC Type 41-940 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service Precautions > Page 6976 Spark Plug: Description and Operation Worn, cracked or dirty plugs may give satisfactory operation at idling speed, but under operating conditions they frequently fail. Faulty plugs are indicated in a number of ways: poor fuel economy, loss of power and speed, hesitation, shudder, medium throttle intake manifold backfire, hard starting and general poor engine performance. Fouled plugs may be indicated by black carbon deposits. The black deposits are usually the result of slow-speed driving and short runs where sufficient engine operating temperature is seldom reached. Worn pistons, rings, faulty ignition, over-rich fuel mixture or low heat range spark plugs may result in carbon deposits. Excessive gap wear on plugs of low mileage, usually indicates the engine is operating at high speeds or loads that are consistently greater than normal or that a plug which is too hot of a heat range is being used. Electrode wear may also be the result of plug overheating, caused by combustion gases leaking past the threads, due to insufficient torque of the spark plug. Excessively lean fuel mixture will also result in excessive electrode wear. Broken insulators are usually the result of improper installation or carelessness when gapping the plug. Broken upper insulators usually result from a poor fitting wrench or an outside blow. The cracked insulator may not show up right away, but will as soon as oil or moisture penetrates the crack. The crack is usually just below the crimped part of shell and may not be visible. Broken lower insulators usually result from carelessness when gapping and generally are visible. This type of break may result from the plug operating too Hot, which may happen in periods of high-speed operation or under heavy loads. When gapping a spark plug, always make the gap adjustment by bending the ground (side) electrode. Spark plugs with broken insulators should always be replaced. Each spark plug boot covers the spark plug terminal and a portion of the plug insulator. These boots prevent flash-overwhich causes engine misfiring. Do not mistake corona discharge for flash-over or a shorted insulator. Corona is a steady blue light appearing around the insulator, just above the shell crimp. It is the visible evidence of high-tension field and has no effect on ignition performance. Usually it can be dust particles leaving a clear ring on the insulator just above the shell. This ring is sometimes mistakenly regarded as evidence that combustion gases have blown out between shell and insulator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service Precautions > Page 6977 Spark Plug: Testing and Inspection Normal spark plug operation will result in brown to grayish-tan deposits appearing on the portion of the spark plug that projects into the cylinder area. A small amount of red-brown, yellow, and white powdery material may also be present on the insulator tip around the center electrode. These deposits are normal combustion by-products of fuels and lubricating oils with additives. Some electrode wear will also occur. Engines which are not running properly are often referred to as misfiring. Spark plug misfiring can be indicated in a number of ways: ^ Poor fuel economy ^ Power loss ^ Loss of speed ^ Hard starting ^ Poor engine performance Flashover occurs when a damaged spark plug boot, along with dirt and moisture, permits the high voltage charge to short over the insulator to the spark plug shell or the engine. Should misfiring occur before the recommended replacement interval, locate and correct the cause. Carbon fouling of the spark plug is indicated by dry, black carbon (soot) deposits on the portion of the spark plug in the cylinder. Excessive idling or slow speeds under light engine loads can keep the spark plug temperatures so low that these deposits are not burned off. Rich fuel mixtures or poor ignition system output may also be the cause. Oil fouling of the spark plug is indicated by wet oily deposits on the portion of the spark plug in the cylinder, usually with little electrode wear. This may be caused by oil getting past worn piston rings or valve seals. This condition also may occur during break-in of new or newly overhauled engines. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service Precautions > Page 6978 Deposit fouling of the spark plug occurs when the normal red-brown, yellow or white deposits of combustion by-products become sufficient to cause misfiring. In some cases, these deposits may melt and form a shiny glaze on the insulator around the center electrode. If the fouling is found in only one or two cylinders, valve stem clearances or intake valve seals may be allowing excess lubricating oil to enter the cylinder, particularly if the deposits are heavier on the side of the spark plug that was facing the intake valve. Excessive gap means that the airspace between the center and side electrodes at the bottom of the spark plug is too wide for consistent spark plug firing. This may be due to improper gap adjustment or to excessive wear of the electrodes during use. Check of the gap size and compare the gap measurement to that specified for the vehicle. Excessive gap wear can be an indication of continuous operation at high speeds or with high engine loads, causing the spark plug to run too hot. Too small of a gap indicates the plug was damaged at the time of installation. Another possible cause is an excessively lean fuel mixture. Low or high spark plug installation torque or improper seating of the spark plug can result in the spark plug running too hot and cause excessive gap wear. The spark plug and cylinder head seats must be in good contact for proper heat transfer and spark plug cooling. Dirty or damaged threads in the head or on the spark plug can keep the spark plug from seating even though the proper torque is applied. Once the spark plugs are properly seated, tighten the spark plug to the proper torque. Low torque may result in poor contact of seats due to a loose spark plug. Overtightening may cause the spark plug shell to be stretched and also result in poor contact between seats. In extreme cases, exhaust blow-by and damage beyond simple gap wear may occur. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service Precautions > Page 6979 Cracked or broken insulators may be the result of improper installation, damage during spark plug regapping, or heat shock to the insulator material. Upper insulators can be broken when a poorly fitting tool is used during installation or removal, or when the spark plug is hit from the outside. Cracks in the upper insulator may be inside the shell and not visible. Also, the breakage may not cause problems until oil or moisture penetrates the crack later. A broken or cracked lower insulator tip (around the center electrode) can result from damage during regapping or from heat shock (spark plug suddenly operating too hot). Damage during regapping can happen if the gapping tool is pushed against the center electrode or the insulator around it, causing the insulator to crack. When regapping a spark plug, make the adjustment by only bending the side electrode. Do not contact other parts. Heat shock breakage in the lower insulator tip generally occurs during severe engine operating conditions (high-speeds or heavy-loading) and may be caused by over advanced timing or low grade fuels. Heat shock refers to a rapid increase in the tip temperature that causes the insulator material to crack. Spark plugs with less than the recommended amount of service can sometimes be cleaned and regapped, then returned to service. However, if there is any doubt about the serviceability of a spark plug, replace it. Replace spark plugs with cracked or broken insulators. In some cases, such as flashover, the ignition wire may need to be changed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service Precautions > Page 6980 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT Removal Procedure Tools Required J38491 Spark Plug Heat Shield Removal Tool 1. Turn OFF the ignition switch. 2. Remove the spark plug wires from the spark plugs. NOTE: ^ Allow the engine to cool before removing the spark plugs. Attempting to remove the spark plugs from a hot engine may cause the plug threads to seize, causing damage to cylinder head threads. ^ Clean the spark plug recess area before removing the spark plug. Failure to do so could result in engine damage because of dirt or foreign material entering the cylinder head, or by the contamination of the cylinder head threads. The contaminated threads may prevent the proper seating of the new plug. Use a thread chaser to clean the threads of any contamination. 3. Remove the spark plugs from the engine. Installation Procedure NOTE: ^ Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the vehicle. Installing spark plugs of another type can severely damage the engine. ^ Check the gap of all new and reconditioned spark plugs before installation. The pre-set gaps may have changed during handling. Use a round feeler gage to ensure an accurate check. Installing the spark plugs with the wrong gap can cause poor engine performance and may even damage the engine. 1. Measure the spark plug gap on the spark plugs to be installed and correct as necessary. Spark Plug Gap: 0.060 in (1.52 mm) NOTE: ^ Be sure that the spark plug threads smoothly into the cylinder head and the spark plug is fully seated. Use a thread chaser, if necessary, to clean threads in the cylinder head. Cross-threading or failing to fully seat the spark plug can cause overheating of the plug, exhaust blow-by, or thread damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service Precautions > Page 6981 2. Install the spark plugs to the engine. Torque: 15 N.m (11 ft. lb.) 3. Connect the spark plug wires to the spark plugs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set Pressure Regulating Solenoid: Customer Interest A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set File In Section: 07 - Transmission/Transaxle Bulletin No.: 0O-07-30-002B Date: July, 2002 TECHNICAL Subject: Slips, Harsh Upshift or Garage Shifts, Launch Shudders, Flares, Erratic Shifts and Intermittent Concerns, DTC P1811 or P0748 Set (Replace Pressure Control Solenoid Valve Assembly) Models: 1997-1999 Buick Riviera 1997-2002 Buick Park Avenue 1998-2002 Buick LeSabre 1999-2002 Buick Regal 2000-2002 Buick Century 2002 Buick Rendezvous 1997-2001 Chevrolet Lumina 1997-2002 Chevrolet Monte Carlo 1999-2002 Chevrolet Venture 2000-2002 Chevrolet Impala 1997-1999 Oldsmobile Eighty Eight 1997-2002 Oldsmobile Silhouette 1998-2002 Oldsmobile Intrigue 2001-2002 Oldsmobile Aurora (3.5L) 1997-2002 Pontiac Bonneville, Grand Prix 1999-2002 Pontiac Transport/Montana 2001-2002 Pontiac Aztek with Hydra-Matic 4T65-E (RPOs MN3, MN7, M15, M76) This bulletin is being revised to add additional models and model years. Please discard Corporate Bulletin Number 00-07-30-002A (Section 07 - Transmission/Transaxle). Condition Some owners of the above vehicles with a HydraMatic 4T65-E transaxle may comment on harsh upshifts or harsh garage shifts, soft shifts, shudders on hard acceleration, or shifts erratic. These conditions may appear intermittently or set a DTC P1811 or P0748. During diagnosis, a low or high line pressure (actual versus desired) may be observed. Cause The above condition may be due to any one of the following which may affect line pressure output: ^ Sediment inside the pressure control (PC) solenoid valve, causing the PC solenoid valve to mechanically bind. ^ Sediment in the valve body, causing the torque signal regulator valve to stick. ^ Incorrect transaxle oil level. Correction Important: Any of the above conditions may be intermittent, therefore, this test should be performed at least three times. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 6993 Refer to the Line Pressure Check Procedure in SI, along with the Line Pressure Specification Table shown, to determine if actual versus desired pressures are within the values specified. The Scan Tool is only able to control the PC solenoid valve in PARK and NEUTRAL with the vehicle stopped. This protects the clutches from extremely high or low pressures in DRIVE or REVERSE ranges. Refer to the Line Pressure Specification Table. The pressures in the table assume a temperature of 70°C. The pressure will vary with a change in temperature. If the actual versus desired pressures are not within the values specified, clean the valve body and replace the PC solenoid valve, if necessary. Check the PC solenoid valve actual versus desired pressures to verify the new PC solenoid valve is responding correctly. Refer to the Automatic Transaxle Section of the Service Manual for the proper repair procedure. Line Pressure Check Procedure Tools Required J 21867 Universal Pressure Gauge Set Important: Before performing a line pressure check, verify that the pressure control (PC) solenoid valve is receiving the correct electrical signal from the PCM. 1. Install a Scan Tool. Caution: Keep the brakes applied at all times in order to prevent unexpected vehicle motion. Personal injury may result it the vehicle moves unexpectedly. 2. Start the engine and set the parking brake. 3. Check for a stored Diagnostic Trouble Code (DTC). 4. Repair the vehicle, if necessary. 5. Check the fluid level. Refer to the Transmission Fluid Checking Procedure. 6. Check the manual linkage for proper adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 6994 7. Turn the engine OFF. Remove the oil pressure test hole plug and install the J 21867. 8. Put the gear selector in PARK range and set the parking brake. 9. Start the engine and allow the engine to warm up at idle. Notice: Total test running time should not be longer than two minutes, or else transmission damage could occur. 10. Access the PC solenoid valve control test on the Scan Tool. 11. Increase the PC solenoid as shown actual current from 0.0 to 1.0 amps in 0.1 amp increments. Allow the pressure to stabilize for five seconds after each pressure change. Read the corresponding line pressure on the J 21867. 12. Refer to the Line Pressure specification table. Compare the data to the table. 13. If pressure readings differ greatly from the table, refer to Incorrect Line Pressure. 14. Remove the J 21867. 15. Apply sealant, P/N 12345382 (in Canada, P/N 10953489), to the oil pressure test hole plug. Notice: Refer to Fastener Notice in Cautions and Notices. 16. Install the oil pressure test hole plug. Tighten Tighten the oil pressure test hole plug to 12 N.m (106 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 6995 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Pressure Control Solenoid Replacement File In Section: 07 - Transmission/Transaxle Bulletin No.: 02-07-30-048 Date: November, 2002 INFORMATION Subject: Pressure Control Solenoid Replacement for 4T65-E, 4T40-E, and 4T45-E Transaxle/Transmission Models: 2000-2003 Buick Century, LeSabre, Park Avenue, Regal 2002-2003 Buick Rendezvous 2000-2001 Chevrolet Lumina 2000-2003 Chevrolet Cavalier, Impala, Malibu, Monte Carlo, Venture 2000-2002 Oldsmobile Intrigue 2000-2003 Oldsmobile Alero, Silhouette 2000-2003 Pontiac Bonneville, Grand Am, Grand Prix, Montana, Sunfire 2001-2003 Pontiac Aztek with RPO Codes MN4, MN5, M13, M15, MN3, MN7 or M76 The pressure control solenoid in the above transaxles has changed for the 2003 models. Important: While the physical dimensions will allow usage of the new solenoid in past model transaxles or usage of the old solenoid in 2003 model transaxles, they should not be interchanged. Interchanging of the pressure control solenoids will result in improper shift characteristics, customer dissatisfaction, and needed repeat repairs. When replacing a pressure control solenoid, be sure to use the correct part number. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement > Page 7001 Parts are currently available from GMSPO. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set Pressure Regulating Solenoid: All Technical Service Bulletins A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set File In Section: 07 - Transmission/Transaxle Bulletin No.: 0O-07-30-002B Date: July, 2002 TECHNICAL Subject: Slips, Harsh Upshift or Garage Shifts, Launch Shudders, Flares, Erratic Shifts and Intermittent Concerns, DTC P1811 or P0748 Set (Replace Pressure Control Solenoid Valve Assembly) Models: 1997-1999 Buick Riviera 1997-2002 Buick Park Avenue 1998-2002 Buick LeSabre 1999-2002 Buick Regal 2000-2002 Buick Century 2002 Buick Rendezvous 1997-2001 Chevrolet Lumina 1997-2002 Chevrolet Monte Carlo 1999-2002 Chevrolet Venture 2000-2002 Chevrolet Impala 1997-1999 Oldsmobile Eighty Eight 1997-2002 Oldsmobile Silhouette 1998-2002 Oldsmobile Intrigue 2001-2002 Oldsmobile Aurora (3.5L) 1997-2002 Pontiac Bonneville, Grand Prix 1999-2002 Pontiac Transport/Montana 2001-2002 Pontiac Aztek with Hydra-Matic 4T65-E (RPOs MN3, MN7, M15, M76) This bulletin is being revised to add additional models and model years. Please discard Corporate Bulletin Number 00-07-30-002A (Section 07 - Transmission/Transaxle). Condition Some owners of the above vehicles with a HydraMatic 4T65-E transaxle may comment on harsh upshifts or harsh garage shifts, soft shifts, shudders on hard acceleration, or shifts erratic. These conditions may appear intermittently or set a DTC P1811 or P0748. During diagnosis, a low or high line pressure (actual versus desired) may be observed. Cause The above condition may be due to any one of the following which may affect line pressure output: ^ Sediment inside the pressure control (PC) solenoid valve, causing the PC solenoid valve to mechanically bind. ^ Sediment in the valve body, causing the torque signal regulator valve to stick. ^ Incorrect transaxle oil level. Correction Important: Any of the above conditions may be intermittent, therefore, this test should be performed at least three times. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7006 Refer to the Line Pressure Check Procedure in SI, along with the Line Pressure Specification Table shown, to determine if actual versus desired pressures are within the values specified. The Scan Tool is only able to control the PC solenoid valve in PARK and NEUTRAL with the vehicle stopped. This protects the clutches from extremely high or low pressures in DRIVE or REVERSE ranges. Refer to the Line Pressure Specification Table. The pressures in the table assume a temperature of 70°C. The pressure will vary with a change in temperature. If the actual versus desired pressures are not within the values specified, clean the valve body and replace the PC solenoid valve, if necessary. Check the PC solenoid valve actual versus desired pressures to verify the new PC solenoid valve is responding correctly. Refer to the Automatic Transaxle Section of the Service Manual for the proper repair procedure. Line Pressure Check Procedure Tools Required J 21867 Universal Pressure Gauge Set Important: Before performing a line pressure check, verify that the pressure control (PC) solenoid valve is receiving the correct electrical signal from the PCM. 1. Install a Scan Tool. Caution: Keep the brakes applied at all times in order to prevent unexpected vehicle motion. Personal injury may result it the vehicle moves unexpectedly. 2. Start the engine and set the parking brake. 3. Check for a stored Diagnostic Trouble Code (DTC). 4. Repair the vehicle, if necessary. 5. Check the fluid level. Refer to the Transmission Fluid Checking Procedure. 6. Check the manual linkage for proper adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7007 7. Turn the engine OFF. Remove the oil pressure test hole plug and install the J 21867. 8. Put the gear selector in PARK range and set the parking brake. 9. Start the engine and allow the engine to warm up at idle. Notice: Total test running time should not be longer than two minutes, or else transmission damage could occur. 10. Access the PC solenoid valve control test on the Scan Tool. 11. Increase the PC solenoid as shown actual current from 0.0 to 1.0 amps in 0.1 amp increments. Allow the pressure to stabilize for five seconds after each pressure change. Read the corresponding line pressure on the J 21867. 12. Refer to the Line Pressure specification table. Compare the data to the table. 13. If pressure readings differ greatly from the table, refer to Incorrect Line Pressure. 14. Remove the J 21867. 15. Apply sealant, P/N 12345382 (in Canada, P/N 10953489), to the oil pressure test hole plug. Notice: Refer to Fastener Notice in Cautions and Notices. 16. Install the oil pressure test hole plug. Tighten Tighten the oil pressure test hole plug to 12 N.m (106 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7008 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Pressure Control Solenoid Replacement File In Section: 07 - Transmission/Transaxle Bulletin No.: 02-07-30-048 Date: November, 2002 INFORMATION Subject: Pressure Control Solenoid Replacement for 4T65-E, 4T40-E, and 4T45-E Transaxle/Transmission Models: 2000-2003 Buick Century, LeSabre, Park Avenue, Regal 2002-2003 Buick Rendezvous 2000-2001 Chevrolet Lumina 2000-2003 Chevrolet Cavalier, Impala, Malibu, Monte Carlo, Venture 2000-2002 Oldsmobile Intrigue 2000-2003 Oldsmobile Alero, Silhouette 2000-2003 Pontiac Bonneville, Grand Am, Grand Prix, Montana, Sunfire 2001-2003 Pontiac Aztek with RPO Codes MN4, MN5, M13, M15, MN3, MN7 or M76 The pressure control solenoid in the above transaxles has changed for the 2003 models. Important: While the physical dimensions will allow usage of the new solenoid in past model transaxles or usage of the old solenoid in 2003 model transaxles, they should not be interchanged. Interchanging of the pressure control solenoids will result in improper shift characteristics, customer dissatisfaction, and needed repeat repairs. When replacing a pressure control solenoid, be sure to use the correct part number. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement > Page 7014 Parts are currently available from GMSPO. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7015 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7016 Pressure Regulating Solenoid: Description and Operation Pressure Control Solenoid Valve The pressure control (PC) solenoid valve is a precision electronic pressure regulator that controls transmission line pressure based on current flow through its coil windings. As current flow is increased, the magnetic field which is produced by the coil moves the solenoid's plunger further away from the exhaust port. Opening the exhaust port decreases the output fluid pressure, which is regulated by the PC solenoid valve. This ultimately decreases line pressure. The PCM controls the PC solenoid valve based upon various inputs including throttle position, fluid temperature, MAP sensor, and gear state. The PCM controls the PC solenoid valve on a positive duty cycle at a fixed frequency of 292.5 Hz (cycles per second). Duty cycle is defined as the percentage of time when current flows through the solenoid coil during each cycle. A higher duty cycle provides a greater current flow through the solenoid. The high (positive) side of the PC solenoid valve electrical circuit at the PCM controls the PC solenoid valve operation. The PCM provides a ground path for the circuit, monitors average current, and continuously varies the PC solenoid valve duty cycle in order to maintain the correct average current flowing through the PC solenoid valve. The PC solenoid valve resistance should measure between 3-5 ohms when measured at 20°C (68°F). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7017 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid Valve Replacement Removal 1. Remove the case side cover. Refer to Control Valve Body Cover Replacement . 2. Disconnect the transaxle wiring harness. 3. Remove the pressure control solenoid (322). Installation 1. Install the pressure control solenoid (322). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 4. Reset the TAP values. Refer to Adapt Function. Adapt Function The 4T65-E transmission uses a line pressure control system, that has the ability to adapt line pressure to compensate for normal wear of the following parts: - The clutch fiber plates - The springs and seals - The apply bands Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7018 The PCM maintains information for the following transmission adaptive systems: Upshift Adapts (1-2, 2-3 and 3-4) The PCM monitors the automatic transmission input shaft speed (AT ISS) sensor and the vehicle speed sensor (VSS) in order to determine when an upshift has started and completed. The PCM measures the time for the upshift. If the upshift time is longer than a calibrated value, then the PCM will adjust the current to the pressure control (PC) solenoid valve to increase the line pressure for the next shift in the same torque range. If the upshift time is shorter than the calibrated value, then the PCM will decrease the line pressure for the next shift in the same torque range. Steady State Adapts The PCM monitors the AT ISS sensor and the VSS after an upshift in order to determine the amount of clutch slippage. If excessive slippage is detected, then the PCM will adjust the current to the PC solenoid valve in order to increase the line pressure to maintain the proper gear ratio for the commanded gear. The TAP information is divided into 13 units, called cells. The cells are numbered 4 through 16. Each cell represents a given torque range. TAP cell 4 is the lowest adaptable torque range and TAP cell 16 is the highest adaptable torque range. It is normal for TAP cell values to display zero or negative numbers. This indicates that the PCM has adjusted line pressure at or below the calibrated base pressure. Clearing Transmission Adaptive Pressure (TAP) Updating TAP information is a learning function of the PCM designed to maintain acceptable shift times. It is not recommended that TAP information be reset unless one of the following repairs has been made: - Transmission overhaul or replacement - Repair or replacement of an apply or release component (clutch, band, piston, servo) - Repair or replacement of a component or assembly which directly affects line pressure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 2. Remove the center console. Refer to Console Replacement - Front Floor (Impala) or Console Replacement - Front Floor (Monte Carlo) in Instrument Panel, Gauges and Warning Indicators. 3. Disconnect electrical connector from the A/T shift lock control (2). 4. Remove both ends of the Automatic Transmission Shift Lock Control from pivot points (1). Installation Procedure 1. Install the A/T shift lock control upper clip onto upper pivot point, and lower clip onto the lower pivot point. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 7022 2. Install the center console. Refer to Console Replacement - Front Floor (Impala) or Console Replacement - Front Floor (Monte Carlo) in Instrument Panel, Gauges and Warning Indicators. 3. Install the electrical connector to the A/T shift lock control. 4. Connect negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 1-2 Shift Solenoid (1-2 SS) Valve Shift Solenoid: Locations 1-2 Shift Solenoid (1-2 SS) Valve Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 1-2 Shift Solenoid (1-2 SS) Valve > Page 7027 Shift Solenoid: Locations 2-3 Shift Solenoid (2-3 SS) Valve Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2, 3-4 Shift Solenoid Valve Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2, 3-4 Shift Solenoid Valve Connector, Wiring Harness Side > Page 7030 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the 1-2 shift solenoid (315A). Installation Procedure 1. Install the 1-2 shift solenoid (315A). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 7033 Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the 2-3 shift solenoid (315B). Installation Procedure 1. Install the 2-3 shift solenoid (315B). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 7034 Shift Solenoid: Service and Repair Solenoids and Wiring Harness Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Use a small flat-bladed tool in order to remove the wiring harness from the solenoid valve(s) (315A, 315B, 322, 334, and/or 440), TFP manual valve position switch (95) and/or the temperature sensor (391). 3. Remove the wiring harness (224). 4. Remove the clips retaining the solenoid(s). 5. Remove the solenoid(s). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 7035 6. Remove the 2-3 shift solenoid (315B). 7. Inspect the wiring harness (224). Installation Procedure 1. Install the 2-3 shift solenoid (315B). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 7036 2. Install the solenoid(s). 3. Install the retaining clips. 4. Install the wiring harness (224). 5. Install the wiring harness to the solenoid valve(s) (315A, 315B, 322, 334, and/or 440), TFP manual valve position switch (395) and/or the temperature sensor (391). 6. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 7040 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 7041 Torque Converter Clutch Solenoid: Service and Repair Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the torque converter clutch PWM solenoid (334). Installation Procedure 1. Install the torque converter clutch PWM solenoid (334). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Fluid Pressure Sensor/Switch: Specifications TFP Switch to Case 120 ft.lb TFP Switch to Case Cover 106 in.lb TFP Switch to Valve Body 70 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 7047 Fluid Pressure Sensor/Switch: Locations Internal Electronic Component Locations Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Fluid Pressure Man Vlv Position Switch Connector, Harness Side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Fluid Pressure Man Vlv Position Switch Connector, Harness Side > Page 7050 Fluid Pressure Sensor/Switch: Diagrams 4T65-E Automatic Transaxle Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Fluid Pressure Manual Valve Position Switch Replacement Fluid Pressure Sensor/Switch: Service and Repair Fluid Pressure Manual Valve Position Switch Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the control valve body bolts (375, 379 and 381) that mount the fluid pressure manual valve position switch to the control valve body (300). 4. Carefully remove the fluid pressure manual valve position switch (395). Handle the switch carefully, the fluid pressure manual valve position switch is very delicate. 5. Inspect the fluid pressure manual valve position switch (395) for the following conditions: - Damaged electrical connector terminals - Damaged seals - Damaged switch membranes - Debris on the switch membranes Installation Procedure 1. Carefully install the fluid pressure manual valve position switch (395). Handle the switch carefully, the fluid pressure manual valve position switch is very delicate. Notice: Refer to Fastener Notice in Service Precautions 2. Install the control valve body bolts (375, 379, and 381) that mount the fluid pressure manual valve position switch to the control valve body (300). - Tighten the control valve body bolt (375) to 12 Nm (106 inch lbs.). - Tighten the control valve body bolt (379) to 16 Nm (106 inch lbs.). - Tighten the control valve body bolt (381) to 8 Nm (70 inch lbs.). 3. Connect the transaxle wiring harness. 4. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Fluid Pressure Manual Valve Position Switch Replacement > Page 7053 Fluid Pressure Sensor/Switch: Service and Repair Pressure Control Solenoid Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the pressure control solenoid (322). Installation Procedure 1. Install the pressure control solenoid (322). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Inside the automatic transaxle Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 7057 Park Neutral Position (PNP) Switch C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 7061 Transmission Speed Sensor: Service and Repair Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the input speed sensor clip (441) from the case cover. 4. Remove the input speed sensor (440) from the case cover. 5. Inspect the input speed sensor (440) for the following conditions: - Damaged or missing magnet - Damaged housing - Bent or missing electrical terminals - Damaged speed sensor clip (441) Installation Procedure 1. Install the input speed sensor (440) into the case cover. 2. Install the input speed sensor clip (441) into the case cover. 3. Connect the transaxle wiring harness. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 7062 4. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Automatic Transaxle Fluid Temperature (TFT) Sensor Transmission Temperature Sensor/Switch: Locations Automatic Transaxle Fluid Temperature (TFT) Sensor Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Automatic Transaxle Fluid Temperature (TFT) Sensor > Page 7067 Transmission Temperature Sensor/Switch: Locations Transaxle Fluid Temperature (TFT) Sensor Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 7068 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 7069 Transmission Temperature Sensor/Switch: Service and Repair Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement 2. Disconnect the wiring harness assembly from the fluid temperature sensor (391). 3. Remove the fluid temperature sensor (391). Installation Procedure 1. Install the fluid temperature sensor (391). 2. Connect the wiring harness assembly to the with fluid temperature sensor (391). 3. Install the case side cover. Refer to Case Side Cover Replacement Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > PROM - Powertrain Control Module Reprogramming PROM - Programmable Read Only Memory: Technical Service Bulletins PROM - Powertrain Control Module Reprogramming File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-053 Date: November, 1999 INFORMATION Subject: Powertrain Control Module (PCM) Reprogramming (Do Not Reprogram Using the Same Download Files as Those Already Present in The Control Module) Models: 1990-2000 Passenger Cars and Trucks with Reprogrammable PCM It is strongly recommended to NOT reinstall the same software and/or calibration download file(s) into the powertrain control module as those that are already present in the PCM. There is no technical reason that the download files inside the PCM would ever become corrupted after the control module had previously been successfully programmed. A P0601 (Control Module Read Only Memory) Diagnostic Trouble Code would set in memory and the MIL would be illuminated if the controller memory became corrupted. The Techline Information System 2000 (TIS 2000) PC, combined with vehicle information gained through the Tech 2, can determine when an attempt to reprogram a PCM using the same download files (as those already in the control module) is being requested. If this is attempted, the TIS 2000 PC currently displays the following message: Notice: THE CALIBRATION SELECTED IS THE CURRENT CALIBRATION IN THE CONTROL MODULE. PROGRAMMING WITH THE SAME DOWNLOAD FILES IS NOT AN EFFECTIVE REPAIR. SELECT ( YES ) TO CONTINUE PROGRAMMING THE CONTROL MODULE,OR ( NO ) TO CANCEL. Effective in the first quarter of 2000, the TIS 2000 PC will indicate: Important: THE CALIBRATION SELECTED IS ALREADY THE CURRENT CALIBRATION IN THE CONTROL MODULE. REPROGRAMMING WITH THE SAME DOWNLOAD FILE IS NOT ALLOWED. Certain learned values, such as: (but not limited to) ^ fuel trim (previously known as block learn memory), ^ IAC learned position in various park/neutral and air conditioning on/off combinations, ^ certain OBDII diagnostic thresholds, ^ automatic transmission shift adapts will revert back to their unlearned starting point values after a reprogramming event occurs. It is feasible that the engine or transmission might temporarily operate differently after a reprogramming event, until these values are re-learned. Relearning occurs while operating the vehicle through normal driving routines. If the same download files are simply reinstalled, any changes noticed in engine operation will likely disappear in a short amount of time and/or driving distance. Reprogramming the control module with the same download files that already exist in the module will only accomplish a warranty claim for a non-effective repair, and a likely comeback. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > PROM - Powertrain Control Module Reprogramming > Page 7074 PROM - Programmable Read Only Memory: Technical Service Bulletins PCM/BCM Replacement DTC's B001/B1271/B1780 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-03-010A Date: June, 2001 INFORMATION Subject: DTCs B1001, B1271 or B1780 Set When Replacing/Reprogramming Other Modules Models: 1999-2002 All Passenger Cars and Trucks With Class 2 Serial Data Communication Between Modules This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 99-06-03-010 (Section 06 - Engine/propulsion System). Class 2 Serial Data Communication allows control modules (i.e. the Powertrain Control Module (PCM), the Body Control Module (BCM), the Dash Integration Module (DIM), the Instrument Panel Cluster (IPC), the radio, the Heating, Ventilation and Air Conditioning (HVAC) Controller, and the Sensing and Diagnostic Module (SDM) to exchange information. This information may be operational information or identification information. Among the identification information exchanged and compared within these modules is the Vehicle Identification Number (VIN). Typically, the PCM broadcasts a portion of the VIN, while another module broadcasts another portion of the VIN. This information is compared by the SDM in order to ensure installation is in the correct vehicle. When the broadcast VIN does not match the VIN stored within the SDM, the following actions occur: ^ DTC B1001 Option Configuration Error is set and deployment of the airbags is inhibited. ^ The VIN information is also used by the radio in order to prevent theft. When the broadcast VIN does not match the VIN stored within the radio, a DTC B1271 ora DTC B1780 Theft Locked is set and the radio is inoperative. This situation may occur when a vehicle is being repaired. When a PCM or a body control type module is replaced, the VIN information must be programmed into the replaced (new) control module. A module which has had VIN information entered into it (for example, one taken from another vehicle) cannot be reprogrammed. VIN information can only be entered into new modules. The ignition must be ON in order to program the control module. Since the VIN information is broadcast when the ignition goes to ON from any other ignition switch position, DTCs may be set in the SDM and/or the radio. Therefore, always follow the specified control module replacement procedures. 1. After completing the repair, turn OFF the ignition for at least 30 seconds. 2. Turn ON the ignition and check for DTCs using a scan tool. If DTCs B1001, B1271, or B178C are present with a history status, DO NOT REPLACE THE SDM OR THE RADIO. 3. Clear the DTCs from all modules using the scan tool. The SDM and/or the radio should then operate properly. 4. Ensure the proper operation of the SDM by turning OFF the ignition and then turning ON the ignition. The air bag warning indicator should flash seven times and then go OFF. Refer to Corporate Bulletin Number 99-09-41-001 for additional information regarding proper reprogramming of the new/replaced module. Clearing codes from the other modules is part of the replacement and reprogramming procedure for the replaced module. The repair is not complete unless all codes have been cleared from all modules. DO NOT SUBMIT CLAIMS FOR OTHER MODULE REPLACEMENTS OR REPROGRAMMING. DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set Pressure Regulating Solenoid: Customer Interest A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set File In Section: 07 - Transmission/Transaxle Bulletin No.: 0O-07-30-002B Date: July, 2002 TECHNICAL Subject: Slips, Harsh Upshift or Garage Shifts, Launch Shudders, Flares, Erratic Shifts and Intermittent Concerns, DTC P1811 or P0748 Set (Replace Pressure Control Solenoid Valve Assembly) Models: 1997-1999 Buick Riviera 1997-2002 Buick Park Avenue 1998-2002 Buick LeSabre 1999-2002 Buick Regal 2000-2002 Buick Century 2002 Buick Rendezvous 1997-2001 Chevrolet Lumina 1997-2002 Chevrolet Monte Carlo 1999-2002 Chevrolet Venture 2000-2002 Chevrolet Impala 1997-1999 Oldsmobile Eighty Eight 1997-2002 Oldsmobile Silhouette 1998-2002 Oldsmobile Intrigue 2001-2002 Oldsmobile Aurora (3.5L) 1997-2002 Pontiac Bonneville, Grand Prix 1999-2002 Pontiac Transport/Montana 2001-2002 Pontiac Aztek with Hydra-Matic 4T65-E (RPOs MN3, MN7, M15, M76) This bulletin is being revised to add additional models and model years. Please discard Corporate Bulletin Number 00-07-30-002A (Section 07 - Transmission/Transaxle). Condition Some owners of the above vehicles with a HydraMatic 4T65-E transaxle may comment on harsh upshifts or harsh garage shifts, soft shifts, shudders on hard acceleration, or shifts erratic. These conditions may appear intermittently or set a DTC P1811 or P0748. During diagnosis, a low or high line pressure (actual versus desired) may be observed. Cause The above condition may be due to any one of the following which may affect line pressure output: ^ Sediment inside the pressure control (PC) solenoid valve, causing the PC solenoid valve to mechanically bind. ^ Sediment in the valve body, causing the torque signal regulator valve to stick. ^ Incorrect transaxle oil level. Correction Important: Any of the above conditions may be intermittent, therefore, this test should be performed at least three times. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7086 Refer to the Line Pressure Check Procedure in SI, along with the Line Pressure Specification Table shown, to determine if actual versus desired pressures are within the values specified. The Scan Tool is only able to control the PC solenoid valve in PARK and NEUTRAL with the vehicle stopped. This protects the clutches from extremely high or low pressures in DRIVE or REVERSE ranges. Refer to the Line Pressure Specification Table. The pressures in the table assume a temperature of 70°C. The pressure will vary with a change in temperature. If the actual versus desired pressures are not within the values specified, clean the valve body and replace the PC solenoid valve, if necessary. Check the PC solenoid valve actual versus desired pressures to verify the new PC solenoid valve is responding correctly. Refer to the Automatic Transaxle Section of the Service Manual for the proper repair procedure. Line Pressure Check Procedure Tools Required J 21867 Universal Pressure Gauge Set Important: Before performing a line pressure check, verify that the pressure control (PC) solenoid valve is receiving the correct electrical signal from the PCM. 1. Install a Scan Tool. Caution: Keep the brakes applied at all times in order to prevent unexpected vehicle motion. Personal injury may result it the vehicle moves unexpectedly. 2. Start the engine and set the parking brake. 3. Check for a stored Diagnostic Trouble Code (DTC). 4. Repair the vehicle, if necessary. 5. Check the fluid level. Refer to the Transmission Fluid Checking Procedure. 6. Check the manual linkage for proper adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7087 7. Turn the engine OFF. Remove the oil pressure test hole plug and install the J 21867. 8. Put the gear selector in PARK range and set the parking brake. 9. Start the engine and allow the engine to warm up at idle. Notice: Total test running time should not be longer than two minutes, or else transmission damage could occur. 10. Access the PC solenoid valve control test on the Scan Tool. 11. Increase the PC solenoid as shown actual current from 0.0 to 1.0 amps in 0.1 amp increments. Allow the pressure to stabilize for five seconds after each pressure change. Read the corresponding line pressure on the J 21867. 12. Refer to the Line Pressure specification table. Compare the data to the table. 13. If pressure readings differ greatly from the table, refer to Incorrect Line Pressure. 14. Remove the J 21867. 15. Apply sealant, P/N 12345382 (in Canada, P/N 10953489), to the oil pressure test hole plug. Notice: Refer to Fastener Notice in Cautions and Notices. 16. Install the oil pressure test hole plug. Tighten Tighten the oil pressure test hole plug to 12 N.m (106 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7088 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Pressure Control Solenoid Replacement File In Section: 07 - Transmission/Transaxle Bulletin No.: 02-07-30-048 Date: November, 2002 INFORMATION Subject: Pressure Control Solenoid Replacement for 4T65-E, 4T40-E, and 4T45-E Transaxle/Transmission Models: 2000-2003 Buick Century, LeSabre, Park Avenue, Regal 2002-2003 Buick Rendezvous 2000-2001 Chevrolet Lumina 2000-2003 Chevrolet Cavalier, Impala, Malibu, Monte Carlo, Venture 2000-2002 Oldsmobile Intrigue 2000-2003 Oldsmobile Alero, Silhouette 2000-2003 Pontiac Bonneville, Grand Am, Grand Prix, Montana, Sunfire 2001-2003 Pontiac Aztek with RPO Codes MN4, MN5, M13, M15, MN3, MN7 or M76 The pressure control solenoid in the above transaxles has changed for the 2003 models. Important: While the physical dimensions will allow usage of the new solenoid in past model transaxles or usage of the old solenoid in 2003 model transaxles, they should not be interchanged. Interchanging of the pressure control solenoids will result in improper shift characteristics, customer dissatisfaction, and needed repeat repairs. When replacing a pressure control solenoid, be sure to use the correct part number. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement > Page 7094 Parts are currently available from GMSPO. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set Pressure Regulating Solenoid: All Technical Service Bulletins A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set File In Section: 07 - Transmission/Transaxle Bulletin No.: 0O-07-30-002B Date: July, 2002 TECHNICAL Subject: Slips, Harsh Upshift or Garage Shifts, Launch Shudders, Flares, Erratic Shifts and Intermittent Concerns, DTC P1811 or P0748 Set (Replace Pressure Control Solenoid Valve Assembly) Models: 1997-1999 Buick Riviera 1997-2002 Buick Park Avenue 1998-2002 Buick LeSabre 1999-2002 Buick Regal 2000-2002 Buick Century 2002 Buick Rendezvous 1997-2001 Chevrolet Lumina 1997-2002 Chevrolet Monte Carlo 1999-2002 Chevrolet Venture 2000-2002 Chevrolet Impala 1997-1999 Oldsmobile Eighty Eight 1997-2002 Oldsmobile Silhouette 1998-2002 Oldsmobile Intrigue 2001-2002 Oldsmobile Aurora (3.5L) 1997-2002 Pontiac Bonneville, Grand Prix 1999-2002 Pontiac Transport/Montana 2001-2002 Pontiac Aztek with Hydra-Matic 4T65-E (RPOs MN3, MN7, M15, M76) This bulletin is being revised to add additional models and model years. Please discard Corporate Bulletin Number 00-07-30-002A (Section 07 - Transmission/Transaxle). Condition Some owners of the above vehicles with a HydraMatic 4T65-E transaxle may comment on harsh upshifts or harsh garage shifts, soft shifts, shudders on hard acceleration, or shifts erratic. These conditions may appear intermittently or set a DTC P1811 or P0748. During diagnosis, a low or high line pressure (actual versus desired) may be observed. Cause The above condition may be due to any one of the following which may affect line pressure output: ^ Sediment inside the pressure control (PC) solenoid valve, causing the PC solenoid valve to mechanically bind. ^ Sediment in the valve body, causing the torque signal regulator valve to stick. ^ Incorrect transaxle oil level. Correction Important: Any of the above conditions may be intermittent, therefore, this test should be performed at least three times. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7099 Refer to the Line Pressure Check Procedure in SI, along with the Line Pressure Specification Table shown, to determine if actual versus desired pressures are within the values specified. The Scan Tool is only able to control the PC solenoid valve in PARK and NEUTRAL with the vehicle stopped. This protects the clutches from extremely high or low pressures in DRIVE or REVERSE ranges. Refer to the Line Pressure Specification Table. The pressures in the table assume a temperature of 70°C. The pressure will vary with a change in temperature. If the actual versus desired pressures are not within the values specified, clean the valve body and replace the PC solenoid valve, if necessary. Check the PC solenoid valve actual versus desired pressures to verify the new PC solenoid valve is responding correctly. Refer to the Automatic Transaxle Section of the Service Manual for the proper repair procedure. Line Pressure Check Procedure Tools Required J 21867 Universal Pressure Gauge Set Important: Before performing a line pressure check, verify that the pressure control (PC) solenoid valve is receiving the correct electrical signal from the PCM. 1. Install a Scan Tool. Caution: Keep the brakes applied at all times in order to prevent unexpected vehicle motion. Personal injury may result it the vehicle moves unexpectedly. 2. Start the engine and set the parking brake. 3. Check for a stored Diagnostic Trouble Code (DTC). 4. Repair the vehicle, if necessary. 5. Check the fluid level. Refer to the Transmission Fluid Checking Procedure. 6. Check the manual linkage for proper adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7100 7. Turn the engine OFF. Remove the oil pressure test hole plug and install the J 21867. 8. Put the gear selector in PARK range and set the parking brake. 9. Start the engine and allow the engine to warm up at idle. Notice: Total test running time should not be longer than two minutes, or else transmission damage could occur. 10. Access the PC solenoid valve control test on the Scan Tool. 11. Increase the PC solenoid as shown actual current from 0.0 to 1.0 amps in 0.1 amp increments. Allow the pressure to stabilize for five seconds after each pressure change. Read the corresponding line pressure on the J 21867. 12. Refer to the Line Pressure specification table. Compare the data to the table. 13. If pressure readings differ greatly from the table, refer to Incorrect Line Pressure. 14. Remove the J 21867. 15. Apply sealant, P/N 12345382 (in Canada, P/N 10953489), to the oil pressure test hole plug. Notice: Refer to Fastener Notice in Cautions and Notices. 16. Install the oil pressure test hole plug. Tighten Tighten the oil pressure test hole plug to 12 N.m (106 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7101 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Pressure Control Solenoid Replacement File In Section: 07 - Transmission/Transaxle Bulletin No.: 02-07-30-048 Date: November, 2002 INFORMATION Subject: Pressure Control Solenoid Replacement for 4T65-E, 4T40-E, and 4T45-E Transaxle/Transmission Models: 2000-2003 Buick Century, LeSabre, Park Avenue, Regal 2002-2003 Buick Rendezvous 2000-2001 Chevrolet Lumina 2000-2003 Chevrolet Cavalier, Impala, Malibu, Monte Carlo, Venture 2000-2002 Oldsmobile Intrigue 2000-2003 Oldsmobile Alero, Silhouette 2000-2003 Pontiac Bonneville, Grand Am, Grand Prix, Montana, Sunfire 2001-2003 Pontiac Aztek with RPO Codes MN4, MN5, M13, M15, MN3, MN7 or M76 The pressure control solenoid in the above transaxles has changed for the 2003 models. Important: While the physical dimensions will allow usage of the new solenoid in past model transaxles or usage of the old solenoid in 2003 model transaxles, they should not be interchanged. Interchanging of the pressure control solenoids will result in improper shift characteristics, customer dissatisfaction, and needed repeat repairs. When replacing a pressure control solenoid, be sure to use the correct part number. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement > Page 7107 Parts are currently available from GMSPO. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7108 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7109 Pressure Regulating Solenoid: Description and Operation Pressure Control Solenoid Valve The pressure control (PC) solenoid valve is a precision electronic pressure regulator that controls transmission line pressure based on current flow through its coil windings. As current flow is increased, the magnetic field which is produced by the coil moves the solenoid's plunger further away from the exhaust port. Opening the exhaust port decreases the output fluid pressure, which is regulated by the PC solenoid valve. This ultimately decreases line pressure. The PCM controls the PC solenoid valve based upon various inputs including throttle position, fluid temperature, MAP sensor, and gear state. The PCM controls the PC solenoid valve on a positive duty cycle at a fixed frequency of 292.5 Hz (cycles per second). Duty cycle is defined as the percentage of time when current flows through the solenoid coil during each cycle. A higher duty cycle provides a greater current flow through the solenoid. The high (positive) side of the PC solenoid valve electrical circuit at the PCM controls the PC solenoid valve operation. The PCM provides a ground path for the circuit, monitors average current, and continuously varies the PC solenoid valve duty cycle in order to maintain the correct average current flowing through the PC solenoid valve. The PC solenoid valve resistance should measure between 3-5 ohms when measured at 20°C (68°F). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7110 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid Valve Replacement Removal 1. Remove the case side cover. Refer to Control Valve Body Cover Replacement . 2. Disconnect the transaxle wiring harness. 3. Remove the pressure control solenoid (322). Installation 1. Install the pressure control solenoid (322). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 4. Reset the TAP values. Refer to Adapt Function. Adapt Function The 4T65-E transmission uses a line pressure control system, that has the ability to adapt line pressure to compensate for normal wear of the following parts: - The clutch fiber plates - The springs and seals - The apply bands Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7111 The PCM maintains information for the following transmission adaptive systems: Upshift Adapts (1-2, 2-3 and 3-4) The PCM monitors the automatic transmission input shaft speed (AT ISS) sensor and the vehicle speed sensor (VSS) in order to determine when an upshift has started and completed. The PCM measures the time for the upshift. If the upshift time is longer than a calibrated value, then the PCM will adjust the current to the pressure control (PC) solenoid valve to increase the line pressure for the next shift in the same torque range. If the upshift time is shorter than the calibrated value, then the PCM will decrease the line pressure for the next shift in the same torque range. Steady State Adapts The PCM monitors the AT ISS sensor and the VSS after an upshift in order to determine the amount of clutch slippage. If excessive slippage is detected, then the PCM will adjust the current to the PC solenoid valve in order to increase the line pressure to maintain the proper gear ratio for the commanded gear. The TAP information is divided into 13 units, called cells. The cells are numbered 4 through 16. Each cell represents a given torque range. TAP cell 4 is the lowest adaptable torque range and TAP cell 16 is the highest adaptable torque range. It is normal for TAP cell values to display zero or negative numbers. This indicates that the PCM has adjusted line pressure at or below the calibrated base pressure. Clearing Transmission Adaptive Pressure (TAP) Updating TAP information is a learning function of the PCM designed to maintain acceptable shift times. It is not recommended that TAP information be reset unless one of the following repairs has been made: - Transmission overhaul or replacement - Repair or replacement of an apply or release component (clutch, band, piston, servo) - Repair or replacement of a component or assembly which directly affects line pressure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 2. Remove the center console. Refer to Console Replacement - Front Floor (Impala) or Console Replacement - Front Floor (Monte Carlo) in Instrument Panel, Gauges and Warning Indicators. 3. Disconnect electrical connector from the A/T shift lock control (2). 4. Remove both ends of the Automatic Transmission Shift Lock Control from pivot points (1). Installation Procedure 1. Install the A/T shift lock control upper clip onto upper pivot point, and lower clip onto the lower pivot point. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 7115 2. Install the center console. Refer to Console Replacement - Front Floor (Impala) or Console Replacement - Front Floor (Monte Carlo) in Instrument Panel, Gauges and Warning Indicators. 3. Install the electrical connector to the A/T shift lock control. 4. Connect negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 1-2 Shift Solenoid (1-2 SS) Valve Shift Solenoid: Locations 1-2 Shift Solenoid (1-2 SS) Valve Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 1-2 Shift Solenoid (1-2 SS) Valve > Page 7120 Shift Solenoid: Locations 2-3 Shift Solenoid (2-3 SS) Valve Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2, 3-4 Shift Solenoid Valve Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2, 3-4 Shift Solenoid Valve Connector, Wiring Harness Side > Page 7123 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the 1-2 shift solenoid (315A). Installation Procedure 1. Install the 1-2 shift solenoid (315A). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 7126 Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the 2-3 shift solenoid (315B). Installation Procedure 1. Install the 2-3 shift solenoid (315B). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 7127 Shift Solenoid: Service and Repair Solenoids and Wiring Harness Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Use a small flat-bladed tool in order to remove the wiring harness from the solenoid valve(s) (315A, 315B, 322, 334, and/or 440), TFP manual valve position switch (95) and/or the temperature sensor (391). 3. Remove the wiring harness (224). 4. Remove the clips retaining the solenoid(s). 5. Remove the solenoid(s). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 7128 6. Remove the 2-3 shift solenoid (315B). 7. Inspect the wiring harness (224). Installation Procedure 1. Install the 2-3 shift solenoid (315B). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 7129 2. Install the solenoid(s). 3. Install the retaining clips. 4. Install the wiring harness (224). 5. Install the wiring harness to the solenoid valve(s) (315A, 315B, 322, 334, and/or 440), TFP manual valve position switch (395) and/or the temperature sensor (391). 6. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 7133 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 7134 Torque Converter Clutch Solenoid: Service and Repair Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the torque converter clutch PWM solenoid (334). Installation Procedure 1. Install the torque converter clutch PWM solenoid (334). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set Pressure Regulating Solenoid: Customer Interest A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set File In Section: 07 - Transmission/Transaxle Bulletin No.: 0O-07-30-002B Date: July, 2002 TECHNICAL Subject: Slips, Harsh Upshift or Garage Shifts, Launch Shudders, Flares, Erratic Shifts and Intermittent Concerns, DTC P1811 or P0748 Set (Replace Pressure Control Solenoid Valve Assembly) Models: 1997-1999 Buick Riviera 1997-2002 Buick Park Avenue 1998-2002 Buick LeSabre 1999-2002 Buick Regal 2000-2002 Buick Century 2002 Buick Rendezvous 1997-2001 Chevrolet Lumina 1997-2002 Chevrolet Monte Carlo 1999-2002 Chevrolet Venture 2000-2002 Chevrolet Impala 1997-1999 Oldsmobile Eighty Eight 1997-2002 Oldsmobile Silhouette 1998-2002 Oldsmobile Intrigue 2001-2002 Oldsmobile Aurora (3.5L) 1997-2002 Pontiac Bonneville, Grand Prix 1999-2002 Pontiac Transport/Montana 2001-2002 Pontiac Aztek with Hydra-Matic 4T65-E (RPOs MN3, MN7, M15, M76) This bulletin is being revised to add additional models and model years. Please discard Corporate Bulletin Number 00-07-30-002A (Section 07 - Transmission/Transaxle). Condition Some owners of the above vehicles with a HydraMatic 4T65-E transaxle may comment on harsh upshifts or harsh garage shifts, soft shifts, shudders on hard acceleration, or shifts erratic. These conditions may appear intermittently or set a DTC P1811 or P0748. During diagnosis, a low or high line pressure (actual versus desired) may be observed. Cause The above condition may be due to any one of the following which may affect line pressure output: ^ Sediment inside the pressure control (PC) solenoid valve, causing the PC solenoid valve to mechanically bind. ^ Sediment in the valve body, causing the torque signal regulator valve to stick. ^ Incorrect transaxle oil level. Correction Important: Any of the above conditions may be intermittent, therefore, this test should be performed at least three times. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7145 Refer to the Line Pressure Check Procedure in SI, along with the Line Pressure Specification Table shown, to determine if actual versus desired pressures are within the values specified. The Scan Tool is only able to control the PC solenoid valve in PARK and NEUTRAL with the vehicle stopped. This protects the clutches from extremely high or low pressures in DRIVE or REVERSE ranges. Refer to the Line Pressure Specification Table. The pressures in the table assume a temperature of 70°C. The pressure will vary with a change in temperature. If the actual versus desired pressures are not within the values specified, clean the valve body and replace the PC solenoid valve, if necessary. Check the PC solenoid valve actual versus desired pressures to verify the new PC solenoid valve is responding correctly. Refer to the Automatic Transaxle Section of the Service Manual for the proper repair procedure. Line Pressure Check Procedure Tools Required J 21867 Universal Pressure Gauge Set Important: Before performing a line pressure check, verify that the pressure control (PC) solenoid valve is receiving the correct electrical signal from the PCM. 1. Install a Scan Tool. Caution: Keep the brakes applied at all times in order to prevent unexpected vehicle motion. Personal injury may result it the vehicle moves unexpectedly. 2. Start the engine and set the parking brake. 3. Check for a stored Diagnostic Trouble Code (DTC). 4. Repair the vehicle, if necessary. 5. Check the fluid level. Refer to the Transmission Fluid Checking Procedure. 6. Check the manual linkage for proper adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7146 7. Turn the engine OFF. Remove the oil pressure test hole plug and install the J 21867. 8. Put the gear selector in PARK range and set the parking brake. 9. Start the engine and allow the engine to warm up at idle. Notice: Total test running time should not be longer than two minutes, or else transmission damage could occur. 10. Access the PC solenoid valve control test on the Scan Tool. 11. Increase the PC solenoid as shown actual current from 0.0 to 1.0 amps in 0.1 amp increments. Allow the pressure to stabilize for five seconds after each pressure change. Read the corresponding line pressure on the J 21867. 12. Refer to the Line Pressure specification table. Compare the data to the table. 13. If pressure readings differ greatly from the table, refer to Incorrect Line Pressure. 14. Remove the J 21867. 15. Apply sealant, P/N 12345382 (in Canada, P/N 10953489), to the oil pressure test hole plug. Notice: Refer to Fastener Notice in Cautions and Notices. 16. Install the oil pressure test hole plug. Tighten Tighten the oil pressure test hole plug to 12 N.m (106 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7147 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Pressure Control Solenoid Replacement File In Section: 07 - Transmission/Transaxle Bulletin No.: 02-07-30-048 Date: November, 2002 INFORMATION Subject: Pressure Control Solenoid Replacement for 4T65-E, 4T40-E, and 4T45-E Transaxle/Transmission Models: 2000-2003 Buick Century, LeSabre, Park Avenue, Regal 2002-2003 Buick Rendezvous 2000-2001 Chevrolet Lumina 2000-2003 Chevrolet Cavalier, Impala, Malibu, Monte Carlo, Venture 2000-2002 Oldsmobile Intrigue 2000-2003 Oldsmobile Alero, Silhouette 2000-2003 Pontiac Bonneville, Grand Am, Grand Prix, Montana, Sunfire 2001-2003 Pontiac Aztek with RPO Codes MN4, MN5, M13, M15, MN3, MN7 or M76 The pressure control solenoid in the above transaxles has changed for the 2003 models. Important: While the physical dimensions will allow usage of the new solenoid in past model transaxles or usage of the old solenoid in 2003 model transaxles, they should not be interchanged. Interchanging of the pressure control solenoids will result in improper shift characteristics, customer dissatisfaction, and needed repeat repairs. When replacing a pressure control solenoid, be sure to use the correct part number. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement > Page 7153 Parts are currently available from GMSPO. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set Pressure Regulating Solenoid: All Technical Service Bulletins A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set File In Section: 07 - Transmission/Transaxle Bulletin No.: 0O-07-30-002B Date: July, 2002 TECHNICAL Subject: Slips, Harsh Upshift or Garage Shifts, Launch Shudders, Flares, Erratic Shifts and Intermittent Concerns, DTC P1811 or P0748 Set (Replace Pressure Control Solenoid Valve Assembly) Models: 1997-1999 Buick Riviera 1997-2002 Buick Park Avenue 1998-2002 Buick LeSabre 1999-2002 Buick Regal 2000-2002 Buick Century 2002 Buick Rendezvous 1997-2001 Chevrolet Lumina 1997-2002 Chevrolet Monte Carlo 1999-2002 Chevrolet Venture 2000-2002 Chevrolet Impala 1997-1999 Oldsmobile Eighty Eight 1997-2002 Oldsmobile Silhouette 1998-2002 Oldsmobile Intrigue 2001-2002 Oldsmobile Aurora (3.5L) 1997-2002 Pontiac Bonneville, Grand Prix 1999-2002 Pontiac Transport/Montana 2001-2002 Pontiac Aztek with Hydra-Matic 4T65-E (RPOs MN3, MN7, M15, M76) This bulletin is being revised to add additional models and model years. Please discard Corporate Bulletin Number 00-07-30-002A (Section 07 - Transmission/Transaxle). Condition Some owners of the above vehicles with a HydraMatic 4T65-E transaxle may comment on harsh upshifts or harsh garage shifts, soft shifts, shudders on hard acceleration, or shifts erratic. These conditions may appear intermittently or set a DTC P1811 or P0748. During diagnosis, a low or high line pressure (actual versus desired) may be observed. Cause The above condition may be due to any one of the following which may affect line pressure output: ^ Sediment inside the pressure control (PC) solenoid valve, causing the PC solenoid valve to mechanically bind. ^ Sediment in the valve body, causing the torque signal regulator valve to stick. ^ Incorrect transaxle oil level. Correction Important: Any of the above conditions may be intermittent, therefore, this test should be performed at least three times. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7158 Refer to the Line Pressure Check Procedure in SI, along with the Line Pressure Specification Table shown, to determine if actual versus desired pressures are within the values specified. The Scan Tool is only able to control the PC solenoid valve in PARK and NEUTRAL with the vehicle stopped. This protects the clutches from extremely high or low pressures in DRIVE or REVERSE ranges. Refer to the Line Pressure Specification Table. The pressures in the table assume a temperature of 70°C. The pressure will vary with a change in temperature. If the actual versus desired pressures are not within the values specified, clean the valve body and replace the PC solenoid valve, if necessary. Check the PC solenoid valve actual versus desired pressures to verify the new PC solenoid valve is responding correctly. Refer to the Automatic Transaxle Section of the Service Manual for the proper repair procedure. Line Pressure Check Procedure Tools Required J 21867 Universal Pressure Gauge Set Important: Before performing a line pressure check, verify that the pressure control (PC) solenoid valve is receiving the correct electrical signal from the PCM. 1. Install a Scan Tool. Caution: Keep the brakes applied at all times in order to prevent unexpected vehicle motion. Personal injury may result it the vehicle moves unexpectedly. 2. Start the engine and set the parking brake. 3. Check for a stored Diagnostic Trouble Code (DTC). 4. Repair the vehicle, if necessary. 5. Check the fluid level. Refer to the Transmission Fluid Checking Procedure. 6. Check the manual linkage for proper adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7159 7. Turn the engine OFF. Remove the oil pressure test hole plug and install the J 21867. 8. Put the gear selector in PARK range and set the parking brake. 9. Start the engine and allow the engine to warm up at idle. Notice: Total test running time should not be longer than two minutes, or else transmission damage could occur. 10. Access the PC solenoid valve control test on the Scan Tool. 11. Increase the PC solenoid as shown actual current from 0.0 to 1.0 amps in 0.1 amp increments. Allow the pressure to stabilize for five seconds after each pressure change. Read the corresponding line pressure on the J 21867. 12. Refer to the Line Pressure specification table. Compare the data to the table. 13. If pressure readings differ greatly from the table, refer to Incorrect Line Pressure. 14. Remove the J 21867. 15. Apply sealant, P/N 12345382 (in Canada, P/N 10953489), to the oil pressure test hole plug. Notice: Refer to Fastener Notice in Cautions and Notices. 16. Install the oil pressure test hole plug. Tighten Tighten the oil pressure test hole plug to 12 N.m (106 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7160 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Pressure Control Solenoid Replacement File In Section: 07 - Transmission/Transaxle Bulletin No.: 02-07-30-048 Date: November, 2002 INFORMATION Subject: Pressure Control Solenoid Replacement for 4T65-E, 4T40-E, and 4T45-E Transaxle/Transmission Models: 2000-2003 Buick Century, LeSabre, Park Avenue, Regal 2002-2003 Buick Rendezvous 2000-2001 Chevrolet Lumina 2000-2003 Chevrolet Cavalier, Impala, Malibu, Monte Carlo, Venture 2000-2002 Oldsmobile Intrigue 2000-2003 Oldsmobile Alero, Silhouette 2000-2003 Pontiac Bonneville, Grand Am, Grand Prix, Montana, Sunfire 2001-2003 Pontiac Aztek with RPO Codes MN4, MN5, M13, M15, MN3, MN7 or M76 The pressure control solenoid in the above transaxles has changed for the 2003 models. Important: While the physical dimensions will allow usage of the new solenoid in past model transaxles or usage of the old solenoid in 2003 model transaxles, they should not be interchanged. Interchanging of the pressure control solenoids will result in improper shift characteristics, customer dissatisfaction, and needed repeat repairs. When replacing a pressure control solenoid, be sure to use the correct part number. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement > Page 7166 Parts are currently available from GMSPO. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7167 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7168 Pressure Regulating Solenoid: Description and Operation Pressure Control Solenoid Valve The pressure control (PC) solenoid valve is a precision electronic pressure regulator that controls transmission line pressure based on current flow through its coil windings. As current flow is increased, the magnetic field which is produced by the coil moves the solenoid's plunger further away from the exhaust port. Opening the exhaust port decreases the output fluid pressure, which is regulated by the PC solenoid valve. This ultimately decreases line pressure. The PCM controls the PC solenoid valve based upon various inputs including throttle position, fluid temperature, MAP sensor, and gear state. The PCM controls the PC solenoid valve on a positive duty cycle at a fixed frequency of 292.5 Hz (cycles per second). Duty cycle is defined as the percentage of time when current flows through the solenoid coil during each cycle. A higher duty cycle provides a greater current flow through the solenoid. The high (positive) side of the PC solenoid valve electrical circuit at the PCM controls the PC solenoid valve operation. The PCM provides a ground path for the circuit, monitors average current, and continuously varies the PC solenoid valve duty cycle in order to maintain the correct average current flowing through the PC solenoid valve. The PC solenoid valve resistance should measure between 3-5 ohms when measured at 20°C (68°F). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7169 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid Valve Replacement Removal 1. Remove the case side cover. Refer to Control Valve Body Cover Replacement . 2. Disconnect the transaxle wiring harness. 3. Remove the pressure control solenoid (322). Installation 1. Install the pressure control solenoid (322). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 4. Reset the TAP values. Refer to Adapt Function. Adapt Function The 4T65-E transmission uses a line pressure control system, that has the ability to adapt line pressure to compensate for normal wear of the following parts: - The clutch fiber plates - The springs and seals - The apply bands Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7170 The PCM maintains information for the following transmission adaptive systems: Upshift Adapts (1-2, 2-3 and 3-4) The PCM monitors the automatic transmission input shaft speed (AT ISS) sensor and the vehicle speed sensor (VSS) in order to determine when an upshift has started and completed. The PCM measures the time for the upshift. If the upshift time is longer than a calibrated value, then the PCM will adjust the current to the pressure control (PC) solenoid valve to increase the line pressure for the next shift in the same torque range. If the upshift time is shorter than the calibrated value, then the PCM will decrease the line pressure for the next shift in the same torque range. Steady State Adapts The PCM monitors the AT ISS sensor and the VSS after an upshift in order to determine the amount of clutch slippage. If excessive slippage is detected, then the PCM will adjust the current to the PC solenoid valve in order to increase the line pressure to maintain the proper gear ratio for the commanded gear. The TAP information is divided into 13 units, called cells. The cells are numbered 4 through 16. Each cell represents a given torque range. TAP cell 4 is the lowest adaptable torque range and TAP cell 16 is the highest adaptable torque range. It is normal for TAP cell values to display zero or negative numbers. This indicates that the PCM has adjusted line pressure at or below the calibrated base pressure. Clearing Transmission Adaptive Pressure (TAP) Updating TAP information is a learning function of the PCM designed to maintain acceptable shift times. It is not recommended that TAP information be reset unless one of the following repairs has been made: - Transmission overhaul or replacement - Repair or replacement of an apply or release component (clutch, band, piston, servo) - Repair or replacement of a component or assembly which directly affects line pressure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 2. Remove the center console. Refer to Console Replacement - Front Floor (Impala) or Console Replacement - Front Floor (Monte Carlo) in Instrument Panel, Gauges and Warning Indicators. 3. Disconnect electrical connector from the A/T shift lock control (2). 4. Remove both ends of the Automatic Transmission Shift Lock Control from pivot points (1). Installation Procedure 1. Install the A/T shift lock control upper clip onto upper pivot point, and lower clip onto the lower pivot point. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 7174 2. Install the center console. Refer to Console Replacement - Front Floor (Impala) or Console Replacement - Front Floor (Monte Carlo) in Instrument Panel, Gauges and Warning Indicators. 3. Install the electrical connector to the A/T shift lock control. 4. Connect negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 1-2 Shift Solenoid (1-2 SS) Valve Shift Solenoid: Locations 1-2 Shift Solenoid (1-2 SS) Valve Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 1-2 Shift Solenoid (1-2 SS) Valve > Page 7179 Shift Solenoid: Locations 2-3 Shift Solenoid (2-3 SS) Valve Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2, 3-4 Shift Solenoid Valve Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2, 3-4 Shift Solenoid Valve Connector, Wiring Harness Side > Page 7182 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the 1-2 shift solenoid (315A). Installation Procedure 1. Install the 1-2 shift solenoid (315A). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 7185 Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the 2-3 shift solenoid (315B). Installation Procedure 1. Install the 2-3 shift solenoid (315B). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 7186 Shift Solenoid: Service and Repair Solenoids and Wiring Harness Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Use a small flat-bladed tool in order to remove the wiring harness from the solenoid valve(s) (315A, 315B, 322, 334, and/or 440), TFP manual valve position switch (95) and/or the temperature sensor (391). 3. Remove the wiring harness (224). 4. Remove the clips retaining the solenoid(s). 5. Remove the solenoid(s). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 7187 6. Remove the 2-3 shift solenoid (315B). 7. Inspect the wiring harness (224). Installation Procedure 1. Install the 2-3 shift solenoid (315B). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 7188 2. Install the solenoid(s). 3. Install the retaining clips. 4. Install the wiring harness (224). 5. Install the wiring harness to the solenoid valve(s) (315A, 315B, 322, 334, and/or 440), TFP manual valve position switch (395) and/or the temperature sensor (391). 6. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 7192 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 7193 Torque Converter Clutch Solenoid: Service and Repair Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the torque converter clutch PWM solenoid (334). Installation Procedure 1. Install the torque converter clutch PWM solenoid (334). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Specifications Accumulator: Specifications Accumulator Cover to Case ................................................................................................................. .................................................................... 106 lb in Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Specifications > Page 7197 Accumulator: Service and Repair Removal Procedure 1. Raise and support the vehicle. Vehicle Lifting. 2. Remove the oil pan. Refer to Oil Pan Replacement. 3. Remove the filter. Refer to Oil Filter and Seal Replacement. 4. Remove the accumulator attaching bolts (131) from the accumulator (132). 5. Remove the manual 2-1 band servo cover bolts (103) from the 2-1 band servo (104). 6. Remove the lube oil pipe (130) from the front differential carrier internal gear lube hole. 7. Remove the accumulator (132) and the manual 2-1 band servo cover (104) as a assembly. 8. Remove the manual 2-1 band servo (106-116). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Specifications > Page 7198 9. To disassemble, inspect and service the accumulator and 2 - 1 manual servo, refer to Refer to Transmission Unit Repair. Installation Procedure 1. Install the manual 2-1 band servo (106-116). 2. Install the lube oil pipe (130) to the front differential carrier internal gear lube hole. 3. Position the manual 2-1 band servo cover (104) and accumulator (132) into place. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the manual 2-1 band servo cover bolts (1103). - Tighten the manual 2-1 band servo cover bolts (103) to 25 Nm (18 ft. lbs.). 5. Install the accumulator attaching bolts (131). - Tighten the accumulator attaching bolts (131) to 12 Nm (106 inch lbs.). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Specifications > Page 7199 6. Install the filter. Refer to Oil Filter and Seal Replacement. 7. Install the oil pan. Refer to Oil Pan Replacement. 8. Lower the vehicle. 9. Refill the automatic transmission with automatic transmission fluid. Refer to Transmission Fluid Checking Procedure. 10. Inspect the automatic transmission for leaks. Refer to Fluid Leak Diagnosis. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: Customer Interest A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover > Page 7208 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: All Technical Service Bulletins A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover > Page 7214 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Page 7215 Band Apply Servo: Specifications 2-1 Servo to Case 18 ft.lb Forward Band Servo Cover to Case 106 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Reverse Servo Replacement Band Apply Servo: Service and Repair Reverse Servo Replacement Removal Procedure 1. Remove the throttle body air inlet duct. Refer to Powertrain Management. 2. Remove the automatic transmission range selector cable lever from the manual shaft. Refer to Automatic Transmission Range Selector Cable Lever Replacement. 3. Depress the reverse servo cover (40). 4. Remove the snap ring (39). 5. Pull the O-ring seal (41) out through the slot in the case. 6. Use side cutting pliers in order to cut the servo cover O-ring seal (41). 7. Depress the reverse servo cover (40), grasp one end of the cut seal (41) and pull the seal (41) out of the servo cover (40). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Reverse Servo Replacement > Page 7218 8. Remove the reverse servo cover (40). 9. Remove the servo assembly (42-48). 10. Remove the servo spring (49). Installation Procedure Important: Follow this procedure exactly or the transaxle will have no reverse gear due to the servo pin missing the band. 1. Jack up the driver side (channel plate side) of the car until it is higher than the differential side. This ensures that the reverse band is in the proper location and not cocked to the channel plate side of the case. 2. Install the servo spring (49). 3. Install the servo assembly (42-48). 4. Install the reverse servo cover (40) with new O-ring seal (41). 5. Install the snap ring (39). 6. Install the automatic transmission range selector cable lever to the manual shaft. Refer to Automatic Transmission Range Selector Cable Lever Replacement 7. Install the throttle body air inlet duct. Refer to Powertrain Management. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Reverse Servo Replacement > Page 7219 Band Apply Servo: Service and Repair Forward Servo Replacement Removal Procedure - Tools Required J 28467-A Engine Support Fixture - J 28467-90 Engine Support Adapter - J 36462 Support Adapter Leg Set 1. Install the J 28467-A. 2. Install the J 28467-90. 3. Install the J 36462. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Remove the power steering gear and hang from the exhaust pipe. Refer to Power Steering Gear Replacement in Steering and Suspension. 6. Remove the transaxle mount lower bolts. Refer to Automatic Transmission Mount Replacement. 7. Remove the engine mount lower bolts. 8. Remove the power steering cooler pipe from the right side of the frame. Refer to Power Steering Cooler Pipe/Hose Replacement in Steering and Suspension. 9. Support the rear of the frame. 10. Loosen the frame bolts. Refer to Frame Removal in Body and Frame. 11. Adjust the jackstand to lower the rear of the frame. 12. Position a drain pan under the forward servo cover. 13. Remove the bolts attaching the servo cover to the transaxle case. 14. Remove the forward servo cover. 15. Remove the forward servo cover O-ring. 16. Remove the servo piston assembly. 17. Remove the servo spring. Installation Procedure 1. Install the servo spring. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Reverse Servo Replacement > Page 7220 2. Install the servo piston assembly. 3. Install the forward servo cover O-ring. 4. Install the forward servo cover. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the forward servo cover attaching bolts. - Tighten the forward servo cover attaching bolts to 12 Nm (106 inch lbs.). 6. Remove the drain pan from under the forward servo cover. 7. Raise the rear of the frame. 8. Install the frame bolts. Refer to Frame Removal in Body and Frame. 9. Remove the support from the rear of the frame. 8. Secure the left wheel drive shaft to the left steering knuckle and strut. 9. Using J 6125-B with J 6125-1B and J 23129, remove the wheel drive shaft oil seal (409) from the transmission (401). Installation Procedure - Tools Required J 34115 Left Side Axle Seal Installer - J 37292-B Axle Seal Protector 1. Use a light wipe of transaxle fluid to lubricate the seal lip. 2. Install the J 37292-B into the new seal (409). 3. Using the J 34115 install a new seal (409). Important: Carefully guide the axle shaft past the lip seal. Do NOT allow the shaft splines to contact any portion of the seal lip surface or damage to the seal will occur. 4. Install the wheel drive shaft to the transaxle. 5. Remove the J 37292-B. 6. Install the left lower ball joint to the lower control arm. Refer to Lower Ball Joint Replacement in Steering and Suspension. 7. Install the left tie rod end to the left steering knuckle. Refer to Tie Rod End Replacement Outer in Steering and Suspension. 8. Install the left stabilizer shaft link to the left lower control arm. Refer to Stabilizer Shaft Link Replacement in Steering and Suspension. 9. Install the left engine splash shield. Refer to Splash Shield Replacement - Engine (Right) or Splash Shield Replacement - Engine (Left) in Body and Frame. 10. Install the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment 11. Lower the vehicle. 12. Refill the automatic transmission with automatic transmission fluid. Refer to Transmission Fluid Checking Procedure. 13. Inspect for automatic transmission fluid leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis Case: Technical Service Bulletins A/T - Cracked Case Diagnosis Bulletin No.: 02-07-30-024B Date: August 18, 2005 INFORMATION Subject: Diagnosis of Cracked or Broken Transmission Case Models: 2006 and Prior Cars and Light Duty Trucks 2006 and Prior HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60/4L60-E/4L65-E or 4L80-E/4L85-E or Allison(R) Series 1000 Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 02-07-30-024A (Section 07 - Transmission/Transaxle). Diagnosing the cause of a cracked or broken transmission case requires additional diagnosis and repair or a repeat failure will occur. A cracked or broken transmission case is most often the result of abnormal external torsional forces acting on the transmission case. If none of the conditions listed below are apparent, an internal transmission component inspection may be required. Repairs of this type may be the result of external damage or abuse for which General Motors is not responsible. They are not the result of defects in materials or workmanship. If in doubt, contact your General Motors Service Representative. The following items should be considered: ^ It is important to inspect the vehicle for signs of an out of line condition, impact damage or foreign material to the following components: - The transmission - The engine mounts - The transmission rear mount and crossmember - Vehicle frame damage that alters the front to rear alignment of the driveshaft - The driveshafts (both front and rear) - The wheels (caked with mud, concrete, etc.) - The tires (roundness, lack of cupping, excessive balance weights) - The transfer case (if the vehicle is 4WD) ^ A worn or damaged driveshaft U-Joint has shown to be a frequent cause of transmission case cracking, especially on vehicles that see extended periods of highway driving. Always inspect the U-joint condition when diagnosing this condition. ^ For driveshaft damage or imbalance, Inspect the driveshafts (both front and rear) for dents, straightness/runout or signs of missing balance weights. Also, inspect for foreign material such as undercoat sprayed on the driveshaft. ^ The driveshaft working angles may be excessive or non-canceling, especially if the vehicle carrying height has been altered (lifted or lowered) or if the frame has been extended or modified. ^ Damaged or worn upper or lower rear control arms or bushings. ^ A rear axle that is not seated in the rear spring properly (leaf spring vehicles). ^ Broken rear springs and or worn leaf spring bushings. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis > Page 7225 In some cases, the customer may not comment about a vibration but it is important to test drive the vehicle while using the electronic vibration analysis tool in an attempt to locate the cause of the torsional vibration. Refer to the Vibration Diagnosis and Correction sub-section of the appropriate Service Manual for more details on diagnosing and correcting vibrations. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 7226 Case: Specifications Tightening Specifications Tightening Specifications Case Cover to Case 106 in.lb Case Cover to Driven Sprocket Support 18 ft.lb Case Cover to Driven Sprocket 106 in.lb Case Side Cover to Case 18 ft.lb Case Side Cover to Case (Stud) 18 ft.lb Case Side Cover to Case (Torx Special) 18 ft.lb Detent Spring to Case Cover 106 in.lb Pump Cover to Case Cover 106 in.lb Case to Drive Sprocket Support 18 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > Case Cover Case: Service and Repair Case Cover Removal Procedure - Tools Required J 28467-A Engine Support Fixture - J 28467-90 Engine Support Adapter - J 36462 Engine Support Adapter Leg Set 1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 2. Remove the throttle body air inlet duct. Refer to Powertrain Management. 3. Install the J 28467-A. 4. Install the J 28467-90. 5. Install the J 36462. 6. Remove the engine mount struts. Refer to Engine Mount Strut Replacement (Left) or Engine Mount Strut Replacement (Right) in Engine. 7. Raise and support the vehicle. Refer to Vehicle Lifting. 8. Remove the left front wheel. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 9. Remove the left engine splash shield. Refer to Splash Shield Replacement Engine (Right) or Splash Shield Replacement - Engine (Left) in Body and Frame. 10. Remove the stabilizer shaft links from the lower control arms. Refer to Stabilizer Shaft Link Replacement in Steering and Suspension. 11. Remove the left tie rod end from the steering knuckle. Refer to Tie Rod End Replacement Outer in Steering and Suspension. 12. Remove the wheel speed sensor harness connector. Refer to Wheel Speed Sensor Replacement (Front) or Wheel Speed Sensor Replacement (Rear) in ABS. 13. Separate the left lower ball joint stud from the left lower control arm. Refer to Lower Ball Joint Replacement in Steering and Suspension. 14. Remove the left wheel drive shaft from the transaxle. 15. Secure the wheel drive shaft to the steering knuckle/strut. Caution: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury. 16. Remove the intermediate steering shaft from the power steering gear stub shaft. Refer to Intermediate Steering Shaft Replacement in Steering and Suspension. 17. Disconnect the three-way catalytic converter pipe from the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust. 18. Support the frame. 19. Remove the transaxle mount bracket. Refer to Automatic Transmission Mount Bracket Replacement. 20. Remove the transaxle mount. Refer to Automatic Transmission Mount Replacement 21. Loosen the engine mount lower nuts. Refer to Powertrain Management. 22. Loosen the right side frame to body bolts. Refer to Frame Removal in Body and Frame. 23. Remove the left side frame to body bolts. Refer to Frame Removal in Body and Frame. 24. Adjust the jackstand to lower the left side of the frame. 25. Position the drain pan under the transaxle. 26. Remove the automatic transmission wiring harness connector. 27. Remove the case side cover bolts (56-58). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > Case Cover > Page 7229 28. Remove the case side cover pan (53). 29. Remove the case side cover gasket (54). 30. Remove the case side cover to automatic transmission case seal (59). 31. Clean the case. 32. Clean the side cover gasket surfaces. Installation Procedure - Tools Required J 28467-A Engine Support Fixture - J 28467-90 Engine Support Adapter - J 36462 Engine Support Adapter Leg Set 1. Install the case side cover gasket (54). 2. Install the case side cover to automatic transmission case seal (59). 3. Install the case side cover pan (53). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > Case Cover > Page 7230 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the case side cover bolts (56-58). - Tighten the case side cover bolts (56-58) to 25 Nm (18 ft. lbs.). 5. Remove the drain pan from under the transaxle. 6. Install the wiring harness connector. 7. Adjust the jackstand to raise the left side of the frame. 8. Install the left side frame to body bolts. Refer to Frame Removal in Body and Frame. 9. Install the right side frame to body bolts. Refer to Frame Removal in Body and Frame. 10. Install the engine mount lower nuts. Refer to Engine Mount and Bracket Replacement in Engine. 11. Install the transaxle mount. Refer to Automatic Transmission Mount Replacement. 12. Install the transaxle mount bracket. Refer to Automatic Transmission Mount Bracket Replacement 13. Remove the jackstand support from the right side of the frame. 14. Remove the jackstand support from the left side of the frame. 15. Connect the three-way catalytic converter pipe to the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust. Caution: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury. 16. Install the intermediate steering shaft to the power steering gear stub shaft. Refer to Intermediate Steering Shaft Replacement in Steering and Suspension. 17. Install the left wheel drive shaft to the transaxle. 18. Install the left lower ball joint stud to the left lower control arm. Refer to Lower Ball Joint Replacement in Steering and Suspension. 19. Install the wheel speed sensor harness connector. Refer to Wheel Speed Sensor Replacement (Front) or Wheel Speed Sensor Replacement (Rear) in ABS. 20. Install the left tie rod end to the steering knuckle. Refer to Tie Rod End Replacement - Outer in Steering and Suspension. 21. Install the stabilizer shaft brackets to the lower control arms. Refer to Stabilizer Shaft Link Replacement in Steering and Suspension. 22. Install the left engine splash shield. Refer to Splash Shield Replacement - Engine (Left) in Body and Frame. 23. Install the left front wheel. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 24. Lower the vehicle. 25. Install the engine mount struts. Refer to Engine Mount Strut Replacement in Engine. 26. Remove J 36462. 27. Remove J 28467-90. 28. Remove J 28467-A. 29. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. Notice: Do NOT overfill the transaxle. The overfilling of the transaxle causes foaming, loss of fluid, shift complaints, and possible damage to the transaxle. 30. Fill the transmission with automatic transmission fluid. Refer to Transmission Fluid Checking Procedure. 31. Inspect for proper completion of the repairs. 32. Inspect for automatic transmission fluid leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > Case Cover > Page 7231 Case: Service and Repair Breather Removal Procedure 1. Remove the throttle body air inlet duct. Refer to Powertrain Management. 2. Remove the transaxle vent (press fit) (37) from the automatic transmission. Installation Procedure 1. Install the transaxle vent (press fit) (37) to the automatic transmission. 2. Install the throttle body air inlet duct. Refer to Powertrain Management. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 7240 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-007A > Feb > 02 > A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL Channel Plate: Customer Interest A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL File In Section: 07 - Transmission/Transaxle Bulletin No.: 00-07-30-007A Date: February, 2002 TECHNICAL Subject: Whine Noise In Park Or Neutral, Service Engine Soon or Service Vehicle Soon Lamp Illuminates (Replace Drive Sprocket Support Bearing) Models: 1999-2000 Buick LeSabre, Park Avenue/Ultra, Regal, Riviera 1999-2000 Chevrolet Lumina, Monte Carlo, Venture 2000 Chevrolet Impala 1999 Oldsmobile Eighty Eight 1999-2000 Oldsmobile Intrigue, Silhouette 1999-2000 Pontiac Bonneville, Grand Prix, Montana with 3.4L, 3.5L or 3.8L Engine (VINs E, H, K, 1-- RPOs LA1, LX5, L36, L67) and Hydra-Matic 4T65-E Transaxle/Transmission (RPOs MN3, MN7, M15) This bulletin is being revised to add the Chevrolet Impala to the models affected. Please discard Corporate Bulletin Number 00-07-30-007 (Section 07 - Transmission/Transaxle). Condition Some owners of the listed models equipped with a Hydra-Matic 4T65-E transaxle with a Julian Date prior to 0045 may comment on a whine noise in PARK and/or NEUTRAL or a Service Engine Soon or Service Vehicle Soon lamp that is illuminated. Upon investigation, a DTC P0741 or P0742 may be found. Cause The above condition may be due to drive sprocket support bearing fluting and/or bearing failure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-007A > Feb > 02 > A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL > Page 7245 Correction Replace the drive sprocket support bearing. Inspect the channel plate and drive sprocket for any abnormal wear, Turbine shaft for cut seals and/or nicks, and chain for excessive play due to failed bearings. Important: When installing the new bearing, the part number MUST be visible (facing upward). Before installing the drive sprocket, lubricate the bearing assembly with J 36850 assembly lubricant. Refer to the 4T65-E Unit Repair Section for the installation procedure. Service Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 7255 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 00-07-30-007A > Feb > 02 > A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL Channel Plate: All Technical Service Bulletins A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL File In Section: 07 - Transmission/Transaxle Bulletin No.: 00-07-30-007A Date: February, 2002 TECHNICAL Subject: Whine Noise In Park Or Neutral, Service Engine Soon or Service Vehicle Soon Lamp Illuminates (Replace Drive Sprocket Support Bearing) Models: 1999-2000 Buick LeSabre, Park Avenue/Ultra, Regal, Riviera 1999-2000 Chevrolet Lumina, Monte Carlo, Venture 2000 Chevrolet Impala 1999 Oldsmobile Eighty Eight 1999-2000 Oldsmobile Intrigue, Silhouette 1999-2000 Pontiac Bonneville, Grand Prix, Montana with 3.4L, 3.5L or 3.8L Engine (VINs E, H, K, 1-- RPOs LA1, LX5, L36, L67) and Hydra-Matic 4T65-E Transaxle/Transmission (RPOs MN3, MN7, M15) This bulletin is being revised to add the Chevrolet Impala to the models affected. Please discard Corporate Bulletin Number 00-07-30-007 (Section 07 - Transmission/Transaxle). Condition Some owners of the listed models equipped with a Hydra-Matic 4T65-E transaxle with a Julian Date prior to 0045 may comment on a whine noise in PARK and/or NEUTRAL or a Service Engine Soon or Service Vehicle Soon lamp that is illuminated. Upon investigation, a DTC P0741 or P0742 may be found. Cause The above condition may be due to drive sprocket support bearing fluting and/or bearing failure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 00-07-30-007A > Feb > 02 > A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL > Page 7260 Correction Replace the drive sprocket support bearing. Inspect the channel plate and drive sprocket for any abnormal wear, Turbine shaft for cut seals and/or nicks, and chain for excessive play due to failed bearings. Important: When installing the new bearing, the part number MUST be visible (facing upward). Before installing the drive sprocket, lubricate the bearing assembly with J 36850 assembly lubricant. Refer to the 4T65-E Unit Repair Section for the installation procedure. Service Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: Customer Interest A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 7274 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 7275 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: All Technical Service Bulletins A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 7281 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 7282 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Ring Gear, A/T > Component Information > Technical Service Bulletins > Customer Interest for Ring Gear: > 00-07-30-007A > Feb > 02 > A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL Ring Gear: Customer Interest A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL File In Section: 07 - Transmission/Transaxle Bulletin No.: 00-07-30-007A Date: February, 2002 TECHNICAL Subject: Whine Noise In Park Or Neutral, Service Engine Soon or Service Vehicle Soon Lamp Illuminates (Replace Drive Sprocket Support Bearing) Models: 1999-2000 Buick LeSabre, Park Avenue/Ultra, Regal, Riviera 1999-2000 Chevrolet Lumina, Monte Carlo, Venture 2000 Chevrolet Impala 1999 Oldsmobile Eighty Eight 1999-2000 Oldsmobile Intrigue, Silhouette 1999-2000 Pontiac Bonneville, Grand Prix, Montana with 3.4L, 3.5L or 3.8L Engine (VINs E, H, K, 1-- RPOs LA1, LX5, L36, L67) and Hydra-Matic 4T65-E Transaxle/Transmission (RPOs MN3, MN7, M15) This bulletin is being revised to add the Chevrolet Impala to the models affected. Please discard Corporate Bulletin Number 00-07-30-007 (Section 07 - Transmission/Transaxle). Condition Some owners of the listed models equipped with a Hydra-Matic 4T65-E transaxle with a Julian Date prior to 0045 may comment on a whine noise in PARK and/or NEUTRAL or a Service Engine Soon or Service Vehicle Soon lamp that is illuminated. Upon investigation, a DTC P0741 or P0742 may be found. Cause The above condition may be due to drive sprocket support bearing fluting and/or bearing failure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Ring Gear, A/T > Component Information > Technical Service Bulletins > Customer Interest for Ring Gear: > 00-07-30-007A > Feb > 02 > A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL > Page 7292 Correction Replace the drive sprocket support bearing. Inspect the channel plate and drive sprocket for any abnormal wear, Turbine shaft for cut seals and/or nicks, and chain for excessive play due to failed bearings. Important: When installing the new bearing, the part number MUST be visible (facing upward). Before installing the drive sprocket, lubricate the bearing assembly with J 36850 assembly lubricant. Refer to the 4T65-E Unit Repair Section for the installation procedure. Service Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Ring Gear, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ring Gear: > 00-07-30-007A > Feb > 02 > A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL Ring Gear: All Technical Service Bulletins A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL File In Section: 07 - Transmission/Transaxle Bulletin No.: 00-07-30-007A Date: February, 2002 TECHNICAL Subject: Whine Noise In Park Or Neutral, Service Engine Soon or Service Vehicle Soon Lamp Illuminates (Replace Drive Sprocket Support Bearing) Models: 1999-2000 Buick LeSabre, Park Avenue/Ultra, Regal, Riviera 1999-2000 Chevrolet Lumina, Monte Carlo, Venture 2000 Chevrolet Impala 1999 Oldsmobile Eighty Eight 1999-2000 Oldsmobile Intrigue, Silhouette 1999-2000 Pontiac Bonneville, Grand Prix, Montana with 3.4L, 3.5L or 3.8L Engine (VINs E, H, K, 1-- RPOs LA1, LX5, L36, L67) and Hydra-Matic 4T65-E Transaxle/Transmission (RPOs MN3, MN7, M15) This bulletin is being revised to add the Chevrolet Impala to the models affected. Please discard Corporate Bulletin Number 00-07-30-007 (Section 07 - Transmission/Transaxle). Condition Some owners of the listed models equipped with a Hydra-Matic 4T65-E transaxle with a Julian Date prior to 0045 may comment on a whine noise in PARK and/or NEUTRAL or a Service Engine Soon or Service Vehicle Soon lamp that is illuminated. Upon investigation, a DTC P0741 or P0742 may be found. Cause The above condition may be due to drive sprocket support bearing fluting and/or bearing failure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Ring Gear, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ring Gear: > 00-07-30-007A > Feb > 02 > A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL > Page 7298 Correction Replace the drive sprocket support bearing. Inspect the channel plate and drive sprocket for any abnormal wear, Turbine shaft for cut seals and/or nicks, and chain for excessive play due to failed bearings. Important: When installing the new bearing, the part number MUST be visible (facing upward). Before installing the drive sprocket, lubricate the bearing assembly with J 36850 assembly lubricant. Refer to the 4T65-E Unit Repair Section for the installation procedure. Service Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Specifications Automatic Transmission Dipstick - Dipstick Tube: Specifications Automatic Transmission Fluid Filler Tube Bracket Bolt 115 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Specifications > Page 7302 Automatic Transmission Dipstick - Dipstick Tube: Service and Repair Removal Procedure 1. Remove the fluid level indicator. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the fluid filler tube bracket bolt from the fluid filler tube bracket. 4. Remove the fluid filler tube. Installation Procedure Important: Do NOT place the fluid filler tube seal on the fluid filler tube when installing the tube or damage to the seal will result. 1. Install the fluid filler tube seal in the transaxle. 2. Position the fluid filler tube. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the fluid filler tube bracket bolt through the fluid filler tube bracket. - Tighten the fluid filler tube bracket bolt to 13 Nm (115 inch lbs.). 4. Lower the vehicle. 5. Install the indicator. 6. Adjust the fluid level. 7. Inspect for fluid leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Drive Chain, A/T > Component Information > Technical Service Bulletins > Customer Interest for Drive Chain: > 00-07-30-007A > Feb > 02 > A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL Drive Chain: Customer Interest A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL File In Section: 07 - Transmission/Transaxle Bulletin No.: 00-07-30-007A Date: February, 2002 TECHNICAL Subject: Whine Noise In Park Or Neutral, Service Engine Soon or Service Vehicle Soon Lamp Illuminates (Replace Drive Sprocket Support Bearing) Models: 1999-2000 Buick LeSabre, Park Avenue/Ultra, Regal, Riviera 1999-2000 Chevrolet Lumina, Monte Carlo, Venture 2000 Chevrolet Impala 1999 Oldsmobile Eighty Eight 1999-2000 Oldsmobile Intrigue, Silhouette 1999-2000 Pontiac Bonneville, Grand Prix, Montana with 3.4L, 3.5L or 3.8L Engine (VINs E, H, K, 1-- RPOs LA1, LX5, L36, L67) and Hydra-Matic 4T65-E Transaxle/Transmission (RPOs MN3, MN7, M15) This bulletin is being revised to add the Chevrolet Impala to the models affected. Please discard Corporate Bulletin Number 00-07-30-007 (Section 07 - Transmission/Transaxle). Condition Some owners of the listed models equipped with a Hydra-Matic 4T65-E transaxle with a Julian Date prior to 0045 may comment on a whine noise in PARK and/or NEUTRAL or a Service Engine Soon or Service Vehicle Soon lamp that is illuminated. Upon investigation, a DTC P0741 or P0742 may be found. Cause The above condition may be due to drive sprocket support bearing fluting and/or bearing failure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Drive Chain, A/T > Component Information > Technical Service Bulletins > Customer Interest for Drive Chain: > 00-07-30-007A > Feb > 02 > A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL > Page 7311 Correction Replace the drive sprocket support bearing. Inspect the channel plate and drive sprocket for any abnormal wear, Turbine shaft for cut seals and/or nicks, and chain for excessive play due to failed bearings. Important: When installing the new bearing, the part number MUST be visible (facing upward). Before installing the drive sprocket, lubricate the bearing assembly with J 36850 assembly lubricant. Refer to the 4T65-E Unit Repair Section for the installation procedure. Service Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Drive Chain, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Chain: > 00-07-30-007A > Feb > 02 > A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL Drive Chain: All Technical Service Bulletins A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL File In Section: 07 - Transmission/Transaxle Bulletin No.: 00-07-30-007A Date: February, 2002 TECHNICAL Subject: Whine Noise In Park Or Neutral, Service Engine Soon or Service Vehicle Soon Lamp Illuminates (Replace Drive Sprocket Support Bearing) Models: 1999-2000 Buick LeSabre, Park Avenue/Ultra, Regal, Riviera 1999-2000 Chevrolet Lumina, Monte Carlo, Venture 2000 Chevrolet Impala 1999 Oldsmobile Eighty Eight 1999-2000 Oldsmobile Intrigue, Silhouette 1999-2000 Pontiac Bonneville, Grand Prix, Montana with 3.4L, 3.5L or 3.8L Engine (VINs E, H, K, 1-- RPOs LA1, LX5, L36, L67) and Hydra-Matic 4T65-E Transaxle/Transmission (RPOs MN3, MN7, M15) This bulletin is being revised to add the Chevrolet Impala to the models affected. Please discard Corporate Bulletin Number 00-07-30-007 (Section 07 - Transmission/Transaxle). Condition Some owners of the listed models equipped with a Hydra-Matic 4T65-E transaxle with a Julian Date prior to 0045 may comment on a whine noise in PARK and/or NEUTRAL or a Service Engine Soon or Service Vehicle Soon lamp that is illuminated. Upon investigation, a DTC P0741 or P0742 may be found. Cause The above condition may be due to drive sprocket support bearing fluting and/or bearing failure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Drive Chain, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Chain: > 00-07-30-007A > Feb > 02 > A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL > Page 7317 Correction Replace the drive sprocket support bearing. Inspect the channel plate and drive sprocket for any abnormal wear, Turbine shaft for cut seals and/or nicks, and chain for excessive play due to failed bearings. Important: When installing the new bearing, the part number MUST be visible (facing upward). Before installing the drive sprocket, lubricate the bearing assembly with J 36850 assembly lubricant. Refer to the 4T65-E Unit Repair Section for the installation procedure. Service Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications Extension Housing: Specifications Case Extension to Case 27 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications > Page 7321 Extension Housing: Service and Repair Removal Procedure 1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Disconnect the right wheel drive shaft from the transaxle. 4. Remove the vehicle speed sensor. Refer to Vehicle Speed Sensor Replacement. 5. Remove the case extension housing bolts (5). 6. Remove the case extension housing (6) with axle seal and the O-ring (8). 7. Inspect the case extension (6) for the following conditions: - A damaged or porous sealing surface for the case extension seal - A damaged or porous sealing surface for the vehicle speed sensor - A damaged or porous sealing surface for the right drive axle oil seal - A damaged or porous sealing surface for the case extension housing - A damaged or worn differential carrier bushing or output shaft bearing - Damaged bolt holes - Inspect the drive axle seal and replace if necessary. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications > Page 7322 1. Perform a differential carrier end play inspection. Refer to Transmission Unit Repair. 2. If removed, install the drive axle seal. Refer to Front Wheel Drive Shaft Oil Seal Replacement (Left) or Front Wheel Drive Shaft Oil Seal Replacement (Right). 3. Install the case extension housing (6) with the axle seal and the O-ring (8). Notice: Refer to Fastener Notice in Service Precautions 4. Install the case extension housing bolts (5). - Tighten the case extension housing bolts (5) to 36 Nm (27 ft. lbs.). 5. Install the vehicle speed sensor. Refer to Vehicle Speed Sensor Replacement. 6. Connect the right wheel drive shaft to the transaxle. 7. Lower the vehicle. 8. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging Notice: Do NOT overfill the transaxle. The overfilling of the transaxle causes foaming, loss of fluid, shift complaints, and possible damage to the transaxle. 9. Refill the transmission. Refer to Transmission Fluid Checking Procedure. 10. Inspect for fluid leaks. Refer to Fluid Leak Diagnosis. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 7327 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 7328 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 7329 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 7330 Fluid - A/T: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Pan Removal ........................................................................................................ ............................................................................................. 7.0L (7.4 Qt) Overhaul ........................... .............................................................................................................................................................. ................. 9.5L (10.0 Qt) Dry .............................................................................................................. .................................................................................................. 12.7L (13.4 Qt) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 7333 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair Removal Procedure 1. Remove the oil pan (24) and the gasket (25). Refer to Oil Pan Replacement. 2. Remove the filter (100). Remove the lip ring seal (101) pressed into the case only if replacement is necessary. 3. Inspect the screen for the following foreign material: - Inspect for metal particles. - Inspect for clutch facing material. - Inspect for rubber particles. - Inspect for engine coolant. 4. Determine the source of the contamination if foreign material is evident. 5. Correct the source of the contamination. 6. Use solvent to clean the screen. 7. Blow-dry the screen. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 7337 1. If removed, install a new seal (101). 2. Install the filter (100), a new filter if required. 3. Install the gasket (25) and the oil pan (24). Refer to Oil Pan Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Fluid Line/Hose: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 7342 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 7343 Fluid Line/Hose: Specifications Automatic Transmission Oil Cooler Hose Fittings 17 ft.lb Automatic Transmission Oil Cooler Hose Retaining Bracket Bolt 18 ft.lb Automatic Transmission Oil Cooler Pipe Clip Bolt 27 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 7344 Fluid Line/Hose: Service and Repair Removal Procedure Notice: Allow sufficient clearance around the transaxle oil cooler pipes and around the hoses to prevent damage or wear which may cause fluid loss. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Position the drain pan. 3. Remove the transaxle oil cooler hoses retaining bracket bolt from the transaxle. 4. Remove the transaxle oil cooler hoses from the transaxle. 5. Remove the lower radiator air deflector. Refer to Radiator Air Baffle Assemblies and Deflectors (Upper) or Radiator Air Baffle Assemblies and Deflectors (Side) or Radiator Air Baffle Assemblies and Deflectors (Lower) in Cooling System. 6. Disconnect the transaxle oil cooler pipes from the fittings at the radiator. Important: Perform the following procedures when removing the retaining ring and transaxle oil cooler pipe from the quick connect fitting on the transmission. 7. Pull the plastic cap back from the quick connect fitting and down along the transaxle oil cooler pipe about two inches. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 7345 8. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 9. Remove the retaining ring from the quick connect fitting. 10. Discard the retaining ring. 11. Pull the transaxle oil cooler pipe straight out from the quick connect fitting. 12. Remove the retaining ring (E-clip) securing the transaxle oil cooler pipe to the quick connect in order to remove the remaining transaxle oil cooler pipes from the remaining quick connect fittings. 13. Remove the transaxle oil cooler pipe clip bolt, 14. Remove the transaxle oil cooler pipes from the vehicle. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 7346 1. Install the transaxle oil cooler pipes. Important: Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. All retaining rings being installed must be new. - Ensure the following procedures are performed when installing the new retaining rings onto the fittings. 2. Install a new retaining ring (E-clip) into the quick connect fitting using the following procedure: 3. Hook one of the open ends of retaining ring in one of the slots in the quick connect fitting. 4. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 7347 5. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 6. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. 7. Install the new retaining ring (E-clip) into the remaining quick connect fittings. Notice: Ensure that the cooler line being installed has a plastic cap on each end that connects to a quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new plastic cap and position on to the cooler line prior to the cooler line installation. 8. Install the transaxle oil cooler pipes to the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 7348 9. Install the transaxle oil cooler pipe into the quick connect fitting. 10. Insert the transaxle oil cooler pipe end into the quick connect fitting until a click is either heard or felt. 11. Do not use the plastic cap on the transaxle oil cooler pipe in order to install the transaxle oil cooler pipe into the fitting. 12. Pull back sharply on the transaxle oil cooler pipe in order to ensure that the transaxle oil cooler pipe is fastened into the quick connect fitting. 13. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 14. Ensure that the plastic cap is fully seated against the fitting. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 7349 15. Ensure that no gap is present between the cap and the fitting. 16. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. A hidden yellow identification band indicates proper joint seating. 17. Do not install the transaxle oil cooler pipe end into the fitting incorrectly. 18. If you cannot position the plastic cap against the fitting, remove the retaining ring from the quick connect fitting per Step 5 of the transaxle oil cooler pipe removal procedure. Check the retaining ring and the transaxle oil cooler pipe end in order to ensure neither is bent. Replace the transaxle oil cooler pipe or the retaining ring if necessary, and install per Step 2 of the transaxle oil cooler pipe installation procedure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 7350 19. Install the transaxle oil cooler hoses to the transaxle. Notice: Refer to Fastener Notice in Service Precautions. 20. Install the transaxle oil cooler pipe clip bolt. - Tighten the transaxle oil cooler pipe clip bolt to 4 Nm (27 inch lbs.). 21. Install the lower radiator air deflector. Refer to Radiator Air Baffle Assemblies and Deflectors (Upper) or Radiator Air Baffle Assemblies and Deflectors (Side) or Radiator Air Baffle Assemblies and Deflectors (Lower) in Cooling System. 22. Lower the vehicle. Notice: Do NOT overfill the transaxle. The overfilling of the transaxle causes foaming, loss of fluid, shift complaints, and possible damage to the transaxle. 23. Adjust the fluid level. Refer to Transmission Fluid Checking Procedure. 24. Inspect for proper completion of the repairs. 25. Inspect for fluid leaks. Refer to Fluid Leak Diagnosis. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications 0il Pan to Case 10 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 7354 Fluid Pan: Service and Repair Removal Procedure Notice: Do NOT use any type of grease to retain parts during the assembly of this unit. Using greases other than the recommended assembly lube changes the transaxle fluid characteristics. Using greases other than the recommended assembly lube causes undesirable shift conditions and/or filter clogging. Use TRANSJEL 36850 or equivalent during the assembly of this unit. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the automatic transmission oil pan. 3. Remove the oil pan bolts (23) from the oil pan. Notice: Ensure care is taken NOT to damage the mating surfaces of the oil pan and of the case or oil leaks may occur. 4. Use a rubber mallet to lightly tap the oil pan or use a screwdriver to pry the oil pan loose. 5. Remove the oil pan (24) from the automatic transmission. 6. Remove the oil pan gasket (25). 7. Inspect the oil pan and the filter screen for the following foreign material: - Inspect for metal particles. - Inspect for clutch facing material. - Inspect for rubber particles. - Inspect for engine coolant. 8. Inspect the oil pan flange (1) for distortion. 9. Replace the oil pan (1) if bent or distorted. Do not attempt to straighten. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 7355 10. Inspect the washers on the oil pan bolts. 11. Install a new bolt and washer assembly if the washer is inverted. Notice: Ensure the oil pan and the case flanges are dry and are free of any oil film or leakage may result. 12. Use solvent to clean the case. 13. Air dry the case. 14. Use solvent to clean the oil pan gasket surfaces. 15. Air dry the oil pan gasket surfaces. 16. Ensure all traces of the old gasket material are removed. Installation Procedure 1. Install the oil pan gasket (25). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 7356 2. Install the oil pan (24) to the automatic transmission. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the oil pan bolts (23). - Tighten the oil pan bolts (23) to 14 Nm (10 ft. lbs.). 4. Lower the vehicle. Notice: Do NOT overfill the transaxle. The overfilling of the transaxle causes foaming, loss of fluid, shift complaints, and possible damage to the transaxle. 5. Refill the automatic transmission with automatic transmission fluid. Refer to Transmission Fluid Checking Procedure. 6. Place the gear selector in the Park position. 7. Start the engine. 8. Run the engine at a slow idle. Do NOT race the engine. 9. Inspect for automatic transmission fluid leaks. 10. Remove the drain pan from under the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Fluid Pressure Sensor/Switch: Specifications TFP Switch to Case 120 ft.lb TFP Switch to Case Cover 106 in.lb TFP Switch to Valve Body 70 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 7360 Fluid Pressure Sensor/Switch: Locations Internal Electronic Component Locations Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Fluid Pressure Man Vlv Position Switch Connector, Harness Side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Fluid Pressure Man Vlv Position Switch Connector, Harness Side > Page 7363 Fluid Pressure Sensor/Switch: Diagrams 4T65-E Automatic Transaxle Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Fluid Pressure Manual Valve Position Switch Replacement Fluid Pressure Sensor/Switch: Service and Repair Fluid Pressure Manual Valve Position Switch Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the control valve body bolts (375, 379 and 381) that mount the fluid pressure manual valve position switch to the control valve body (300). 4. Carefully remove the fluid pressure manual valve position switch (395). Handle the switch carefully, the fluid pressure manual valve position switch is very delicate. 5. Inspect the fluid pressure manual valve position switch (395) for the following conditions: - Damaged electrical connector terminals - Damaged seals - Damaged switch membranes - Debris on the switch membranes Installation Procedure 1. Carefully install the fluid pressure manual valve position switch (395). Handle the switch carefully, the fluid pressure manual valve position switch is very delicate. Notice: Refer to Fastener Notice in Service Precautions 2. Install the control valve body bolts (375, 379, and 381) that mount the fluid pressure manual valve position switch to the control valve body (300). - Tighten the control valve body bolt (375) to 12 Nm (106 inch lbs.). - Tighten the control valve body bolt (379) to 16 Nm (106 inch lbs.). - Tighten the control valve body bolt (381) to 8 Nm (70 inch lbs.). 3. Connect the transaxle wiring harness. 4. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Fluid Pressure Manual Valve Position Switch Replacement > Page 7366 Fluid Pressure Sensor/Switch: Service and Repair Pressure Control Solenoid Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the pressure control solenoid (322). Installation Procedure 1. Install the pressure control solenoid (322). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L65E, 4L60E, 4L60, 200-4R Oil Pump Spring Fluid Pump: Technical Service Bulletins A/T - 4L65E, 4L60E, 4L60, 200-4R Oil Pump Spring Bulletin No.: 04-07-30-006 Date: February 11, 2004 INFORMATION Subject: 4L65-E, 4L60-E, 4L60 and 200-4R Automatic Transmission Oil Pump Spring First and Second Design Identification Models: 2004 and Prior Passenger Cars and Light Duty Trucks 2003-2004 HUMMER H2 with 4L65-E, 4L60-E, 4L60 or 200-4R Automatic Transmission The purpose of this bulletin is to identify the oil pump spring usage for the two different pump designs. Manufacturing of the first design oil pump springs ended December 15, 2003. Manufacturing of the second design oil pump spring began December 16, 2003 The first design oil pump springs (206) and (207) DO NOT have any identification markings. The first design springs (206) and (207) use an inner and outer spring, two springs. The second design oil pump spring (245) is identified with tapered ends on the spring (245) as shown above. The second design spring (245) is a single spring. When servicing either (first design or second design) oil pump body, use the new single oil pump spring (245) with tapered ends. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L65E, 4L60E, 4L60, 200-4R Oil Pump Spring > Page 7371 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 7372 Fluid Pump: Service and Repair Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. Notice: Do NOT remove the three bolts which hold the pump together. 2. Remove the oil pump bolts (205-207). 3. Remove the oil pump (200) form the valve body (300). 4. Inspect the oil pump. Refer to Transmission Unit Repair. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 7373 1. Install the oil pump (200) to the valve body (300). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil pump bolts (205-207). - Tighten the M6 X 1.0 X 20 bolt to 8 Nm (70 inch lbs.). - Tighten the M6 X 1.0 X 85 bolt to 12 Nm (106 inch lbs.). - Tighten the M6 X 1.0 X 95 bolt to 16 Nm (12 ft. lbs.). 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Hydraulic Thermo Valve, A/T > Component Information > Service and Repair Hydraulic Thermo Valve: Service and Repair Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the oil pan. Refer to Oil Pan Replacement. 3. Remove the thermo element pins and washers (120 and 123). 4. Remove the thermo element (121) and the thermo element plate (122). Installation Procedure - Tools Required J 34094-A Thermo Element Height Gauge 1. Use the J 34094-A to set the middle thermo pin (123). 2. Install the new thermo element plate (122). 3. Install the pin and washer (120). 4. Use the J 34094-A to set the height of the pin and washer (120) furthest from the accumulator. 5. Use the J 34094-A to set the height of the second pin and washer (120). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Hydraulic Thermo Valve, A/T > Component Information > Service and Repair > Page 7377 6. Carefully install the thermo element (121) between the two pins (120). The V in the thermo element (121) must contact the thermo element plate (122). 7. Install the oil pan. Refer to Oil Pan Replacement 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > Page 7382 Output Shaft: Service and Repair Removal Procedure - Tools Required J 42562 Axle Removal Wedge 1. Remove the case extension housing. Refer to Case Extension Housing Replacement. 2. Remove the left wheel drive shaft from the transaxle. 3. Rotate the differential carrier until the end of the output shaft can be seen and the differential pinion shaft (701) is in a horizontal position. 4. Place the J 42562 between the end of the output shaft and the differential pinion shaft. 5. Using a hammer, hit the end of the axle removal tool in order to compress the output shaft compression ring (512) and push the output shaft through the differential side gear. 6. Remove the differential carrier (700). 7. Using snap ring pliers remove the compression ring (512) from the output shaft. 8. Remove the output shaft through the left wheel opening. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > Page 7383 9. Inspect the output shaft (510) for the following: - Stripped splines - A damaged retainer ring groove Installation Procedure 1. Install the drive axle retainer ring (509) and the output shaft differential inboard snap ring (512) onto the output shaft (510). 2. Hold the front differential carrier (700) in place and carefully install the output shaft (510) into the transmission through the left wheel opening. Extend the output shaft through the differential side gear. 3. Install the left wheel drive shaft to the transaxle. 4. Install the case extension housing. Refer to Case Extension Housing Replacement Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Adjustments Parking Lock Cable: Adjustments Adjustment Procedure 1. Place the shift lever in the PARK position. 2. Place the ignition key in the LOCK position. 3. Ensure the shift lever cannot move to another position. The ignition key should be removable from the ignition lock cylinder. 4. Place the ignition key in the RUN position. 5. Place the shift lever in the NEUTRAL position. 6. Ensure that the ignition key cannot turn to the LOCK position. 7. The system is properly adjusted if the above conditions are met. Proceed to step 13. 8. If the above conditions are not met proceed with the adjustment procedure. 9. Pull the cable connector lock back to the UP position. 10. Readjust the cable connector as outlined. 10.1. Push the cable connector nose forward to remove the slack. 10.2. Push the cable connector lock button down. 11. Recheck the operation. 12. If the ignition key cannot be removed in the PARK position, then pull the connector lock button to the UP position. 13. Move the cable connector nose rearward until the key can be removed from the ignition. 14. Push the lock button down. 15. Reinstall the cable into the clips to provide the correct routing. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Adjustments > Page 7387 Parking Lock Cable: Service and Repair Removal Procedure 1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging 2. Remove the console. Refer to Console Replacement - Front Floor (Impala) or Console Replacement - Front Floor (Monte Carlo) in Instrument Panel, Gauges and Warning Indicators. 3. To gain access to the park/lock cable at the steering column. Refer to Steering Column Filler Replacement in Instrument Panel, Gauges and Warning Indicators. 4. Place the transaxle shift control lever in the PARK position. Important: Ensure the ignition key is in the RUN position. Do NOT attempt to proceed to Step 6 with the key in any other position. 5. Turn the ignition key to the RUN position. 6. Slip a screwdriver blade into the slot provided in the ignition switch inhibitor. 7. Use the screwdriver to depress the cable latch. 8. Pull the cable from the inhibitor. 9. Remove the park/lock cable at the shift control. 10. Remove the cable retainer from the park/lock cable at the shift control. 11. Remove the park/lock cable. Installation Procedure 1. Ensure the cable lock button is in the UP position. 2. Ensure the shift lever is in the PARK position. 3. Install the park/lock cable. 4. Snap the cable connector into the shifter base. 5. Install the cable retainer to the park/lock cable at the shift control. 6. Ensure the ignition key is in the RUN position. 7. Install the cable into the inhibitor housing. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Adjustments > Page 7388 Important: Ensure the ignition key is in the LOCK position. Do NOT attempt to insert the cable with the key in any other position. 8. Turn the ignition key to the LOCK position. 9. Install the cable end onto the shifter park lock lever pin. 10. Push the cable connector nose forward to remove the slack. 11. Push the cable connector lock button down using no load applied to the connector nose. 12. Inspect the operation of the park/lock cable for proper adjustment. Refer to Park Lock Cable Adjustment. 13. Install the console. Refer to Console Replacement - Front Floor (Impala) or Console Replacement Front Floor (Monte Carlo) in Instrument Panel, Gauges and Warning Indicators. 14. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Technical Service Bulletins > A/T - Grinding/Growling Noise in Park on Incline Parking Pawl: Technical Service Bulletins A/T - Grinding/Growling Noise in Park on Incline INFORMATION Bulletin No.: 99-07-30-030F Date: May 01, 2008 Subject: Grinding and/or Growling Noise in Park on Incline Models: 2009 and Prior Passenger Cars and Light Duty Trucks (Including Saturn) with Hydra-Matic Front Wheel Drive (FWD) Automatic Transmissions Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 99-07-30-030E (Section 07 - Transmission/Transaxle). Service Information Owners of some vehicles equipped with Hydra-Matic front wheel drive transaxles may comment on a grinding and/or growling noise that is noticeable when standing in PARK on a hill or slope with the engine running and the parking brake not applied. Under these conditions, the weight of the vehicle puts a load on the parking pawl which can create a "ground-out" path through the drive axles, front struts, springs and spring towers. Normal engine noise can be transmitted to the passenger compartment through the "ground-out" path. Owners concerned about this condition should be advised to apply the parking brake prior to shifting into PARK. This is the recommended procedure described in the Owners Manual. Applying the parking brake first will put the load of the vehicle on the rear brakes rather than on the parking pawl. Refer the owner to the appropriate Owner Manual for additional details and instructions. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set Pressure Regulating Solenoid: Customer Interest A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set File In Section: 07 - Transmission/Transaxle Bulletin No.: 0O-07-30-002B Date: July, 2002 TECHNICAL Subject: Slips, Harsh Upshift or Garage Shifts, Launch Shudders, Flares, Erratic Shifts and Intermittent Concerns, DTC P1811 or P0748 Set (Replace Pressure Control Solenoid Valve Assembly) Models: 1997-1999 Buick Riviera 1997-2002 Buick Park Avenue 1998-2002 Buick LeSabre 1999-2002 Buick Regal 2000-2002 Buick Century 2002 Buick Rendezvous 1997-2001 Chevrolet Lumina 1997-2002 Chevrolet Monte Carlo 1999-2002 Chevrolet Venture 2000-2002 Chevrolet Impala 1997-1999 Oldsmobile Eighty Eight 1997-2002 Oldsmobile Silhouette 1998-2002 Oldsmobile Intrigue 2001-2002 Oldsmobile Aurora (3.5L) 1997-2002 Pontiac Bonneville, Grand Prix 1999-2002 Pontiac Transport/Montana 2001-2002 Pontiac Aztek with Hydra-Matic 4T65-E (RPOs MN3, MN7, M15, M76) This bulletin is being revised to add additional models and model years. Please discard Corporate Bulletin Number 00-07-30-002A (Section 07 - Transmission/Transaxle). Condition Some owners of the above vehicles with a HydraMatic 4T65-E transaxle may comment on harsh upshifts or harsh garage shifts, soft shifts, shudders on hard acceleration, or shifts erratic. These conditions may appear intermittently or set a DTC P1811 or P0748. During diagnosis, a low or high line pressure (actual versus desired) may be observed. Cause The above condition may be due to any one of the following which may affect line pressure output: ^ Sediment inside the pressure control (PC) solenoid valve, causing the PC solenoid valve to mechanically bind. ^ Sediment in the valve body, causing the torque signal regulator valve to stick. ^ Incorrect transaxle oil level. Correction Important: Any of the above conditions may be intermittent, therefore, this test should be performed at least three times. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7401 Refer to the Line Pressure Check Procedure in SI, along with the Line Pressure Specification Table shown, to determine if actual versus desired pressures are within the values specified. The Scan Tool is only able to control the PC solenoid valve in PARK and NEUTRAL with the vehicle stopped. This protects the clutches from extremely high or low pressures in DRIVE or REVERSE ranges. Refer to the Line Pressure Specification Table. The pressures in the table assume a temperature of 70°C. The pressure will vary with a change in temperature. If the actual versus desired pressures are not within the values specified, clean the valve body and replace the PC solenoid valve, if necessary. Check the PC solenoid valve actual versus desired pressures to verify the new PC solenoid valve is responding correctly. Refer to the Automatic Transaxle Section of the Service Manual for the proper repair procedure. Line Pressure Check Procedure Tools Required J 21867 Universal Pressure Gauge Set Important: Before performing a line pressure check, verify that the pressure control (PC) solenoid valve is receiving the correct electrical signal from the PCM. 1. Install a Scan Tool. Caution: Keep the brakes applied at all times in order to prevent unexpected vehicle motion. Personal injury may result it the vehicle moves unexpectedly. 2. Start the engine and set the parking brake. 3. Check for a stored Diagnostic Trouble Code (DTC). 4. Repair the vehicle, if necessary. 5. Check the fluid level. Refer to the Transmission Fluid Checking Procedure. 6. Check the manual linkage for proper adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7402 7. Turn the engine OFF. Remove the oil pressure test hole plug and install the J 21867. 8. Put the gear selector in PARK range and set the parking brake. 9. Start the engine and allow the engine to warm up at idle. Notice: Total test running time should not be longer than two minutes, or else transmission damage could occur. 10. Access the PC solenoid valve control test on the Scan Tool. 11. Increase the PC solenoid as shown actual current from 0.0 to 1.0 amps in 0.1 amp increments. Allow the pressure to stabilize for five seconds after each pressure change. Read the corresponding line pressure on the J 21867. 12. Refer to the Line Pressure specification table. Compare the data to the table. 13. If pressure readings differ greatly from the table, refer to Incorrect Line Pressure. 14. Remove the J 21867. 15. Apply sealant, P/N 12345382 (in Canada, P/N 10953489), to the oil pressure test hole plug. Notice: Refer to Fastener Notice in Cautions and Notices. 16. Install the oil pressure test hole plug. Tighten Tighten the oil pressure test hole plug to 12 N.m (106 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7403 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Pressure Control Solenoid Replacement File In Section: 07 - Transmission/Transaxle Bulletin No.: 02-07-30-048 Date: November, 2002 INFORMATION Subject: Pressure Control Solenoid Replacement for 4T65-E, 4T40-E, and 4T45-E Transaxle/Transmission Models: 2000-2003 Buick Century, LeSabre, Park Avenue, Regal 2002-2003 Buick Rendezvous 2000-2001 Chevrolet Lumina 2000-2003 Chevrolet Cavalier, Impala, Malibu, Monte Carlo, Venture 2000-2002 Oldsmobile Intrigue 2000-2003 Oldsmobile Alero, Silhouette 2000-2003 Pontiac Bonneville, Grand Am, Grand Prix, Montana, Sunfire 2001-2003 Pontiac Aztek with RPO Codes MN4, MN5, M13, M15, MN3, MN7 or M76 The pressure control solenoid in the above transaxles has changed for the 2003 models. Important: While the physical dimensions will allow usage of the new solenoid in past model transaxles or usage of the old solenoid in 2003 model transaxles, they should not be interchanged. Interchanging of the pressure control solenoids will result in improper shift characteristics, customer dissatisfaction, and needed repeat repairs. When replacing a pressure control solenoid, be sure to use the correct part number. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement > Page 7409 Parts are currently available from GMSPO. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set Pressure Regulating Solenoid: All Technical Service Bulletins A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set File In Section: 07 - Transmission/Transaxle Bulletin No.: 0O-07-30-002B Date: July, 2002 TECHNICAL Subject: Slips, Harsh Upshift or Garage Shifts, Launch Shudders, Flares, Erratic Shifts and Intermittent Concerns, DTC P1811 or P0748 Set (Replace Pressure Control Solenoid Valve Assembly) Models: 1997-1999 Buick Riviera 1997-2002 Buick Park Avenue 1998-2002 Buick LeSabre 1999-2002 Buick Regal 2000-2002 Buick Century 2002 Buick Rendezvous 1997-2001 Chevrolet Lumina 1997-2002 Chevrolet Monte Carlo 1999-2002 Chevrolet Venture 2000-2002 Chevrolet Impala 1997-1999 Oldsmobile Eighty Eight 1997-2002 Oldsmobile Silhouette 1998-2002 Oldsmobile Intrigue 2001-2002 Oldsmobile Aurora (3.5L) 1997-2002 Pontiac Bonneville, Grand Prix 1999-2002 Pontiac Transport/Montana 2001-2002 Pontiac Aztek with Hydra-Matic 4T65-E (RPOs MN3, MN7, M15, M76) This bulletin is being revised to add additional models and model years. Please discard Corporate Bulletin Number 00-07-30-002A (Section 07 - Transmission/Transaxle). Condition Some owners of the above vehicles with a HydraMatic 4T65-E transaxle may comment on harsh upshifts or harsh garage shifts, soft shifts, shudders on hard acceleration, or shifts erratic. These conditions may appear intermittently or set a DTC P1811 or P0748. During diagnosis, a low or high line pressure (actual versus desired) may be observed. Cause The above condition may be due to any one of the following which may affect line pressure output: ^ Sediment inside the pressure control (PC) solenoid valve, causing the PC solenoid valve to mechanically bind. ^ Sediment in the valve body, causing the torque signal regulator valve to stick. ^ Incorrect transaxle oil level. Correction Important: Any of the above conditions may be intermittent, therefore, this test should be performed at least three times. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7414 Refer to the Line Pressure Check Procedure in SI, along with the Line Pressure Specification Table shown, to determine if actual versus desired pressures are within the values specified. The Scan Tool is only able to control the PC solenoid valve in PARK and NEUTRAL with the vehicle stopped. This protects the clutches from extremely high or low pressures in DRIVE or REVERSE ranges. Refer to the Line Pressure Specification Table. The pressures in the table assume a temperature of 70°C. The pressure will vary with a change in temperature. If the actual versus desired pressures are not within the values specified, clean the valve body and replace the PC solenoid valve, if necessary. Check the PC solenoid valve actual versus desired pressures to verify the new PC solenoid valve is responding correctly. Refer to the Automatic Transaxle Section of the Service Manual for the proper repair procedure. Line Pressure Check Procedure Tools Required J 21867 Universal Pressure Gauge Set Important: Before performing a line pressure check, verify that the pressure control (PC) solenoid valve is receiving the correct electrical signal from the PCM. 1. Install a Scan Tool. Caution: Keep the brakes applied at all times in order to prevent unexpected vehicle motion. Personal injury may result it the vehicle moves unexpectedly. 2. Start the engine and set the parking brake. 3. Check for a stored Diagnostic Trouble Code (DTC). 4. Repair the vehicle, if necessary. 5. Check the fluid level. Refer to the Transmission Fluid Checking Procedure. 6. Check the manual linkage for proper adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7415 7. Turn the engine OFF. Remove the oil pressure test hole plug and install the J 21867. 8. Put the gear selector in PARK range and set the parking brake. 9. Start the engine and allow the engine to warm up at idle. Notice: Total test running time should not be longer than two minutes, or else transmission damage could occur. 10. Access the PC solenoid valve control test on the Scan Tool. 11. Increase the PC solenoid as shown actual current from 0.0 to 1.0 amps in 0.1 amp increments. Allow the pressure to stabilize for five seconds after each pressure change. Read the corresponding line pressure on the J 21867. 12. Refer to the Line Pressure specification table. Compare the data to the table. 13. If pressure readings differ greatly from the table, refer to Incorrect Line Pressure. 14. Remove the J 21867. 15. Apply sealant, P/N 12345382 (in Canada, P/N 10953489), to the oil pressure test hole plug. Notice: Refer to Fastener Notice in Cautions and Notices. 16. Install the oil pressure test hole plug. Tighten Tighten the oil pressure test hole plug to 12 N.m (106 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7416 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Pressure Control Solenoid Replacement File In Section: 07 - Transmission/Transaxle Bulletin No.: 02-07-30-048 Date: November, 2002 INFORMATION Subject: Pressure Control Solenoid Replacement for 4T65-E, 4T40-E, and 4T45-E Transaxle/Transmission Models: 2000-2003 Buick Century, LeSabre, Park Avenue, Regal 2002-2003 Buick Rendezvous 2000-2001 Chevrolet Lumina 2000-2003 Chevrolet Cavalier, Impala, Malibu, Monte Carlo, Venture 2000-2002 Oldsmobile Intrigue 2000-2003 Oldsmobile Alero, Silhouette 2000-2003 Pontiac Bonneville, Grand Am, Grand Prix, Montana, Sunfire 2001-2003 Pontiac Aztek with RPO Codes MN4, MN5, M13, M15, MN3, MN7 or M76 The pressure control solenoid in the above transaxles has changed for the 2003 models. Important: While the physical dimensions will allow usage of the new solenoid in past model transaxles or usage of the old solenoid in 2003 model transaxles, they should not be interchanged. Interchanging of the pressure control solenoids will result in improper shift characteristics, customer dissatisfaction, and needed repeat repairs. When replacing a pressure control solenoid, be sure to use the correct part number. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement > Page 7422 Parts are currently available from GMSPO. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7423 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7424 Pressure Regulating Solenoid: Description and Operation Pressure Control Solenoid Valve The pressure control (PC) solenoid valve is a precision electronic pressure regulator that controls transmission line pressure based on current flow through its coil windings. As current flow is increased, the magnetic field which is produced by the coil moves the solenoid's plunger further away from the exhaust port. Opening the exhaust port decreases the output fluid pressure, which is regulated by the PC solenoid valve. This ultimately decreases line pressure. The PCM controls the PC solenoid valve based upon various inputs including throttle position, fluid temperature, MAP sensor, and gear state. The PCM controls the PC solenoid valve on a positive duty cycle at a fixed frequency of 292.5 Hz (cycles per second). Duty cycle is defined as the percentage of time when current flows through the solenoid coil during each cycle. A higher duty cycle provides a greater current flow through the solenoid. The high (positive) side of the PC solenoid valve electrical circuit at the PCM controls the PC solenoid valve operation. The PCM provides a ground path for the circuit, monitors average current, and continuously varies the PC solenoid valve duty cycle in order to maintain the correct average current flowing through the PC solenoid valve. The PC solenoid valve resistance should measure between 3-5 ohms when measured at 20°C (68°F). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7425 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid Valve Replacement Removal 1. Remove the case side cover. Refer to Control Valve Body Cover Replacement . 2. Disconnect the transaxle wiring harness. 3. Remove the pressure control solenoid (322). Installation 1. Install the pressure control solenoid (322). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 4. Reset the TAP values. Refer to Adapt Function. Adapt Function The 4T65-E transmission uses a line pressure control system, that has the ability to adapt line pressure to compensate for normal wear of the following parts: - The clutch fiber plates - The springs and seals - The apply bands Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7426 The PCM maintains information for the following transmission adaptive systems: Upshift Adapts (1-2, 2-3 and 3-4) The PCM monitors the automatic transmission input shaft speed (AT ISS) sensor and the vehicle speed sensor (VSS) in order to determine when an upshift has started and completed. The PCM measures the time for the upshift. If the upshift time is longer than a calibrated value, then the PCM will adjust the current to the pressure control (PC) solenoid valve to increase the line pressure for the next shift in the same torque range. If the upshift time is shorter than the calibrated value, then the PCM will decrease the line pressure for the next shift in the same torque range. Steady State Adapts The PCM monitors the AT ISS sensor and the VSS after an upshift in order to determine the amount of clutch slippage. If excessive slippage is detected, then the PCM will adjust the current to the PC solenoid valve in order to increase the line pressure to maintain the proper gear ratio for the commanded gear. The TAP information is divided into 13 units, called cells. The cells are numbered 4 through 16. Each cell represents a given torque range. TAP cell 4 is the lowest adaptable torque range and TAP cell 16 is the highest adaptable torque range. It is normal for TAP cell values to display zero or negative numbers. This indicates that the PCM has adjusted line pressure at or below the calibrated base pressure. Clearing Transmission Adaptive Pressure (TAP) Updating TAP information is a learning function of the PCM designed to maintain acceptable shift times. It is not recommended that TAP information be reset unless one of the following repairs has been made: - Transmission overhaul or replacement - Repair or replacement of an apply or release component (clutch, band, piston, servo) - Repair or replacement of a component or assembly which directly affects line pressure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 7435 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 7441 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 7442 Seals and Gaskets: By Symptom Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 7443 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 7444 To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Front Wheel Drive Shaft Oil Seal Replacement (Left) Seals and Gaskets: Service and Repair Front Wheel Drive Shaft Oil Seal Replacement (Left) - J 23129 Axle Seal Remover - J 6125-1B Slide Hammer Adapter - J 6125-B Slide Hammer 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Remove the left engine splash shield. Refer to Splash Shield Replacement - Engine (Right) or Splash Shield Replacement - Engine (Left) in Body and Frame. 4. Remove the stabilizer shaft links from the left lower control arm. Refer to Stabilizer Shaft Link Replacement in Steering and Suspension. 5. Remove the left tie rod end from the left steering knuckle. Refer to Tie Rod End Replacement - Outer in Steering and Suspension. 6. Remove the left lower ball joint from the lower control arm. Refer to Lower Ball Joint Replacement in Steering and Suspension. 7. Remove the left wheel drive shaft from the transaxle. 8. Secure the left wheel drive shaft to the left steering knuckle and strut. 9. Using J 6125-B with J 6125-1B and J 23129, remove the wheel drive shaft oil seal (409) from the transmission (401). Installation Procedure Tools Required - J 34115 Left Side Axle Seal Installer - J 37292-B Axle Seal Protector 1. Use a light wipe of Transaxle fluid to lubricate the seal lip. 2. Install the J 37292-B into the new seal (409). 3. Using the J 34115 install a new seal (409). Important: Carefully guide the axle shaft past the lip seal. Do NOT allow the shaft splines to contact any portion of the seal lip surface or damage to the seal will occur. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Front Wheel Drive Shaft Oil Seal Replacement (Left) > Page 7447 4. Install the wheel drive shaft to the transaxle. 5. Remove the J 37292-B 6. Install the lower ball joint to the lower control arm. Refer to Lower Ball Joint Replacement in Steering and Suspension. 7. Install the left tie rod end to the left steering knuckle. Refer to the Tie Rod End Replacement Outer in Steering and Suspension. 8. Install the left stabilizer shaft link to the lower control arm. Refer to Stabilizer Shaft Link Replacement in Steering and Suspension. 9 Install the left engine splash shield. Refer to Splash Shield Replacement - Engine (Right) or Splash Shield Replacement - Engine (Left) in Body and Frame. 10. Install the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment 11. Lower the vehicle. 12. Refill the automatic transmission with automatic transmission fluid. Refer to Transmission Fluid Checking Procedure. 13. Inspect the automatic transmission fluid leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Front Wheel Drive Shaft Oil Seal Replacement (Left) > Page 7448 Seals and Gaskets: Service and Repair Front Wheel Drive Shaft Oil Seal Replacement (Right) Removal Procedure - J 23129 Axle Seal Remover - J 6125-1B Slide Hammer Adapter - J 6125-B Slide Hammer 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Remove the right engine splash shield. Refer to Splash Shield Replacement - Engine (Right) in Body and Frame. 4. Remove the right stabilizer shaft links from the right lower control arm. Refer to Stabilizer Shaft Link Replacement in Steering and Suspension. 5. Remove the right tie rod end from the right steering knuckle. Refer to Tie Rod End Replacement - Outer in Steering and Suspension. 6. Remove the right lower ball joint from the lower control arm. Refer to Lower Ball Joint Replacement. 7. Remove the right wheel drive shaft from the transaxle. 8. Secure the right wheel drive shaft to the right steering knuckle and strut. 9. Using the J 6125-B with the J 6125-IB and the J 23129 remove the wheel drive shaft oil seal from the transmission. Installation Procedure - Tools Required J 29130 Right Side Axle Seal Installer - J 37292-B Axle Seal Protector 1. Use a light wipe of transaxle fluid to lubricate the seal lip. 2. Install the J 37292-B into the new seal (4). 3. Using the J 29130 install the new seal (4). Important: Carefully guide the axle shaft past the lip seal. Do NOT allow the shaft splines to contact any portion of the seal lip surface or damage to the seal will occur. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Front Wheel Drive Shaft Oil Seal Replacement (Left) > Page 7449 4. Install the wheel drive shaft to the transaxle. 5. Install the right lower ball joint to the steering knuckle. Refer to Lower Ball Joint Replacement in Steering and Suspension. 6. Install the right tie rod end to the steering knuckle. Refer to Tie Rod End Replacement - Outer in Steering and Suspension. 7. Install the right stabilizer shaft links to the right lower control arm. Refer to Stabilizer Shaft Link Replacement in Steering and Suspension. 8. Install the right engine splash shield. 9. Install the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 10. Lower the vehicle. 11. Refill the automatic transmission with automatic transmission fluid. Refer to Transmission Fluid Checking Procedure. 12. Inspect for automatic transmission fluid leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Fluid Pressure Sensor/Switch: Specifications TFP Switch to Case 120 ft.lb TFP Switch to Case Cover 106 in.lb TFP Switch to Valve Body 70 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 7454 Fluid Pressure Sensor/Switch: Locations Internal Electronic Component Locations Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Fluid Pressure Man Vlv Position Switch Connector, Harness Side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Fluid Pressure Man Vlv Position Switch Connector, Harness Side > Page 7457 Fluid Pressure Sensor/Switch: Diagrams 4T65-E Automatic Transaxle Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Fluid Pressure Manual Valve Position Switch Replacement Fluid Pressure Sensor/Switch: Service and Repair Fluid Pressure Manual Valve Position Switch Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the control valve body bolts (375, 379 and 381) that mount the fluid pressure manual valve position switch to the control valve body (300). 4. Carefully remove the fluid pressure manual valve position switch (395). Handle the switch carefully, the fluid pressure manual valve position switch is very delicate. 5. Inspect the fluid pressure manual valve position switch (395) for the following conditions: - Damaged electrical connector terminals - Damaged seals - Damaged switch membranes - Debris on the switch membranes Installation Procedure 1. Carefully install the fluid pressure manual valve position switch (395). Handle the switch carefully, the fluid pressure manual valve position switch is very delicate. Notice: Refer to Fastener Notice in Service Precautions 2. Install the control valve body bolts (375, 379, and 381) that mount the fluid pressure manual valve position switch to the control valve body (300). - Tighten the control valve body bolt (375) to 12 Nm (106 inch lbs.). - Tighten the control valve body bolt (379) to 16 Nm (106 inch lbs.). - Tighten the control valve body bolt (381) to 8 Nm (70 inch lbs.). 3. Connect the transaxle wiring harness. 4. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Fluid Pressure Manual Valve Position Switch Replacement > Page 7460 Fluid Pressure Sensor/Switch: Service and Repair Pressure Control Solenoid Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the pressure control solenoid (322). Installation Procedure 1. Install the pressure control solenoid (322). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Inside the automatic transaxle Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 7464 Park Neutral Position (PNP) Switch C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 7468 Transmission Speed Sensor: Service and Repair Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the input speed sensor clip (441) from the case cover. 4. Remove the input speed sensor (440) from the case cover. 5. Inspect the input speed sensor (440) for the following conditions: - Damaged or missing magnet - Damaged housing - Bent or missing electrical terminals - Damaged speed sensor clip (441) Installation Procedure 1. Install the input speed sensor (440) into the case cover. 2. Install the input speed sensor clip (441) into the case cover. 3. Connect the transaxle wiring harness. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 7469 4. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Automatic Transaxle Fluid Temperature (TFT) Sensor Transmission Temperature Sensor/Switch: Locations Automatic Transaxle Fluid Temperature (TFT) Sensor Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Automatic Transaxle Fluid Temperature (TFT) Sensor > Page 7474 Transmission Temperature Sensor/Switch: Locations Transaxle Fluid Temperature (TFT) Sensor Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 7475 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 7476 Transmission Temperature Sensor/Switch: Service and Repair Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement 2. Disconnect the wiring harness assembly from the fluid temperature sensor (391). 3. Remove the fluid temperature sensor (391). Installation Procedure 1. Install the fluid temperature sensor (391). 2. Connect the wiring harness assembly to the with fluid temperature sensor (391). 3. Install the case side cover. Refer to Case Side Cover Replacement Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 2. Remove the center console. Refer to Console Replacement - Front Floor (Impala) or Console Replacement - Front Floor (Monte Carlo) in Instrument Panel, Gauges and Warning Indicators. 3. Disconnect electrical connector from the A/T shift lock control (2). 4. Remove both ends of the Automatic Transmission Shift Lock Control from pivot points (1). Installation Procedure 1. Install the A/T shift lock control upper clip onto upper pivot point, and lower clip onto the lower pivot point. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 7481 2. Install the center console. Refer to Console Replacement - Front Floor (Impala) or Console Replacement - Front Floor (Monte Carlo) in Instrument Panel, Gauges and Warning Indicators. 3. Install the electrical connector to the A/T shift lock control. 4. Connect negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > 1-2 Shift Solenoid (1-2 SS) Valve Shift Solenoid: Locations 1-2 Shift Solenoid (1-2 SS) Valve Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > 1-2 Shift Solenoid (1-2 SS) Valve > Page 7486 Shift Solenoid: Locations 2-3 Shift Solenoid (2-3 SS) Valve Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > 1-2, 3-4 Shift Solenoid Valve Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > 1-2, 3-4 Shift Solenoid Valve Connector, Wiring Harness Side > Page 7489 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the 1-2 shift solenoid (315A). Installation Procedure 1. Install the 1-2 shift solenoid (315A). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 7492 Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the 2-3 shift solenoid (315B). Installation Procedure 1. Install the 2-3 shift solenoid (315B). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 7493 Shift Solenoid: Service and Repair Solenoids and Wiring Harness Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Use a small flat-bladed tool in order to remove the wiring harness from the solenoid valve(s) (315A, 315B, 322, 334, and/or 440), TFP manual valve position switch (95) and/or the temperature sensor (391). 3. Remove the wiring harness (224). 4. Remove the clips retaining the solenoid(s). 5. Remove the solenoid(s). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 7494 6. Remove the 2-3 shift solenoid (315B). 7. Inspect the wiring harness (224). Installation Procedure 1. Install the 2-3 shift solenoid (315B). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 7495 2. Install the solenoid(s). 3. Install the retaining clips. 4. Install the wiring harness (224). 5. Install the wiring harness to the solenoid valve(s) (315A, 315B, 322, 334, and/or 440), TFP manual valve position switch (395) and/or the temperature sensor (391). 6. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications Shifter A/T: Specifications Console Shift Control Nuts 18 ft.lb Automatic Transmission Range Selector Cable Bracket Bolts 15 ft.lb Automatic Transmission Range Selector Lever Nut 15 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Automatic Transmission Range Selector Cable Lever Replacement Shifter A/T: Service and Repair Automatic Transmission Range Selector Cable Lever Replacement Removal Procedure 1. Remove the throttle body air inlet duct. Refer to Powertrain Management. 2. Remove the automatic transaxle range selector lever cable from the automatic transaxle range selector lever 3. Remove the automatic transaxle range selector lever retaining nut. 4. Remove the automatic transaxle range selector lever from the automatic transaxle. Installation Procedure 1. Install the automatic transaxle range selector lever to the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Automatic Transmission Range Selector Cable Lever Replacement > Page 7501 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the automatic transaxle range selector lever retaining nut. - Tighten the automatic transaxle range selector lever retaining nut to 20 Nm (15 ft. lbs.). 3. Install the automatic transaxle range selector lever cable to the automatic transaxle range selector lever. 4. Adjust the automatic transaxle range selector lever cable if necessary. Refer to Automatic Transmission Range Selector Cable Adjustment 5. Install the throttle body air inlet duct. Refer to Powertrain Management. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Automatic Transmission Range Selector Cable Lever Replacement > Page 7502 Shifter A/T: Service and Repair Shift Control Replacement Removal Procedure 1. Remove the Console Trim Plate. Refer to Trim Plate Replacement - Front Floor Console (Impala) or Trim Plate Replacement - Front Floor Console (Monte Carlo) or Console Replacement - Front Floor (Impala) or Console Replacement Front Floor (Monte Carlo) in Instrument Panel, Gauges and Warning Indicators. 2. Remove the console wiring harness. 3. Remove the console shift control wiring harness. 4. Remove the automatic transaxle range selector cable. Refer to Automatic Transmission Range Selector Cable Replacement (New Cable Installation Only) or Automatic Transmission Range Selector Cable Replacement (At Manual Shaft) or Automatic Transmission Range Selector Cable Replacement (At Console Shift Control) or Automatic Transmission Range Selector Cable Replacement (At Column Shift Control). 5. Remove the park/lock cable. Refer to Park Lock Cable Replacement. 6. Disconnect the light bulb and the retainer from the shifter. 7. Remove the console shift control retaining nuts. 8. Remove the console shift control assembly from the vehicle. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Automatic Transmission Range Selector Cable Lever Replacement > Page 7503 1. Install the console shift control into the vehicle. Notice: Refer to Fastener Notice in Service Precautions 2. Install the console shift control retaining nuts. - Tighten the console shift control retaining nuts to 24 Nm (18 ft. lbs.). 3. Install the park/lock cable. Refer to Park Lock Cable Replacement. 4. Install the automatic transaxle range selector cable. Refer to Automatic Transmission Range Selector Cable Replacement (New Cable Installation Only) or Automatic Transmission Range Selector Cable Replacement (At Manual Shaft) or Automatic Transmission Range Selector Cable Replacement (At Console Shift Control) or Automatic Transmission Range Selector Cable Replacement (At Column Shift Control). 5. Install the console shift control wiring harness. 6. Install the console wiring harness. 7. Install the console trim plate. Refer to Trim Plate Replacement - Front Floor Console (Impala) or Trim Plate Replacement - Front Floor Console (Monte Carlo) or Console Replacement Front Floor (Impala) or Console Replacement Front Floor (Monte Carlo) in Instrument Panel, Gauges and Warning Indicators. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 00-07-30-018 > Nov > 00 > Shift Lever/Ignition Cylinder - High Effort To Move Technical Service Bulletin # 00-07-30-018 Date: 001101 Shift Lever/Ignition Cylinder - High Effort To Move File In Section: 07 - Transmission/Transaxle Bulletin No.: 00-07-30-018 Date: November, 2000 Subject: High Effort Required to Turn Ignition key and Remove Shift Lever from Park Position (Replace Transmission Shift Control Cable Assembly and Fasteners) Models: 2000 Chevrolet Impala 2000 Pontiac Bonneville with column shift only Condition Some owners of vehicles that have the transmission shift lever mounted on the steering column may comment that they have difficulty removing the transmission shift lever from the park position. In addition, some may also comment that it takes a high amount of effort to rotate or turn the ignition key. Cause The steering column mounted transmission linear shift control cable that attaches to the ignition switch may be too long and may also be routed incorrectly. Correction Replace the steering column mounted transmission linear shift control and cable assembly with a new assembly that has a shorter cable and an adjustment feature. Use the following service procedure for installing and adjusting. For additional information and fastener torque specifications, see the Steering Column sub-section in the Steering section, and the Instrument Panel sub-section in the Body and Accessories section of the appropriate Service Manual. Parts Information IMPALA MODELS BONNEVILLE MODEL Parts are currently available from GMSPO. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 00-07-30-018 > Nov > 00 > Shift Lever/Ignition Cylinder - High Effort To Move > Page 7513 For vehicles repaired under warranty, use the table. Disclaimer Impala Service Procedure 1. Disable the SIR system. 2. Remove the left side lower instrument panel insulator. 3. Remove the lower steering column filler panel. 4. Remove the aluminum knee bolster bracket. 5. Remove the tilt ever. 6. Remove the lower steering column cover. 7. Remove the upper steering column cover. 8. Remove the two nuts attaching the column to the column support and lower the column. Important: The plastic tie bands removed in the next step have to be reinstalled or replaced when servicing the linear shift control cable assembly. Also do not remove the plastic tie bands from the new assembly. 9. Remove (cut) any plastic tie bands that secure or route the cable assembly to the ignition switch. 10. Depress the black tab on the end of the cable and pull the cable out of the backside of the ignition switch/lock cylinder assembly. 11. Disconnect the transmission shift cable and the brake/transmission shift interlock red from tee linear shift control cable assembly. 12. Remove the shift lever retaining screw. Discard the screw and remove the lever. 13. Remove the three screws that attach the linear shift control cable assembly to the steering column and discard the three screws. 14. Remove the linear shift control cable assembly from the steering column and vehicle. 15. Install the new linear shift control cable assembly, P/N 26064241, on the steering column secure with three new screws, P/N 26020231. 16. Install the shift lever and secure with new screw, P/N 26086313. 17. Connect the transmission shift cable and the brake/transmission shift interlock rod to the linear shift control cable assembly. 18. Insert the cable into the backside of the ignition switch/lock cylinder assembly and lock in place. 19. Raise the steering column to the column support and secure with two nuts. 20. Verify cable routing for clearance with brake switches. 21. Move the shift lever from PARK to reverse and back to the PARK position and turn the ignition key to the OFF position. 22. Verify that shift lever cannot be removed from PARK when the ignition key is in the OFF position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 00-07-30-018 > Nov > 00 > Shift Lever/Ignition Cylinder - High Effort To Move > Page 7514 23. Turn the ignition key to the ON position and verify that the shift lever can be removed from PARK. 24. Return the shift lever to the PARK position and verify that the ignition key can be turned to the OFF position and removed without difficulty. If key can be removed without difficulty, proceed to Step 28. If the key cannot be removed or requires high effort, proceed to Step 25. 25. Adjust the cable length by moving the white adjustment tab outwards from the adjuster body located in the middle of the cable. 26. Move the shift lever from PARK to reverse and back to the PARK position and turn the ignition key to the OFF position. 27. Press the white adjustment tab inwards until it locks in place. Verify proper operation by performing Steps 21-24. 28. Install the upper steering column cover. 29. Install the lower steering column cover and position the shift lever seal in place. 30. Install the tilt lever. 31. Install the aluminum knee bolster bracket. 32. Install the lower steering column filler panel. 33. Install the left side lower instrument panel filler. 34. Enable the SIR system. Bonneville Service Procedure 1. Disable SIR system. 2. Remove left side lower instrument panel insulator. 3. Remove the driver's side knee bolster cover. 4. Remove the driver's side knee bolster. 5. Remove the ignition lock/switch bezel. 6. Remove the instrument cluster bezel. 7. Remove the tilt lever. 8. Remove the lower steering column cover. 9. Remove the upper steering column cover. 10. Remove two nuts and loosen two bolts to lower steering column for access to linear shift control cable assembly. Important: The plastic tie bands removed in the next step have to be reinstalled or replaced when servicing the linear shift control cable assembly. Also, do not remove the plastic tie bands from the new assembly. 11. Remove (cut) any plastic tie bands that secure or route the cable assembly to the ignition switch. 12. Disconnect the transmission shift cable and the brake/transmission safety interlock rod from the linear shift control cable assembly. 13. Remove the shift lever retaining screw. Discard the screw and remove the shift lever. 14. Remove the three screws attaching the linear shift control cable assembly to the steering column and discard the screws. 15. Remove the radio assembly. 16. Remove the ignition lock/switch assembly from the instrument panel. 17. Depress the black tab on the end of the cable and pull the cable out of the backside of the ignition lock/switch assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 00-07-30-018 > Nov > 00 > Shift Lever/Ignition Cylinder - High Effort To Move > Page 7515 18. Remove the linear shift control cable assembly from the steering column and vehicle. 19. Install the new linear shift control cable assembly, P/N 26089928, on the steering column and secure with three new screws, P/N 26071469. 20. Install the shift lever and secure with new screw, P/N 26086318. 21. Connect the transmission shift cable and the brake/transmission shift interlock rod to the linear shift control cable assembly. 22. Insert the cable into the backside of the ignition lock/switch assembly and lock into place. 23. Install the ignition lock/switch assembly in the instrument panel. 24. Raise the steering column and install and the tighten nuts and bolts. 25. Verify cable routing for clearance with brake switches. 26. Move the shift lever from the PARK position to reverse and back to the PARK position and turn the ignition key to the OFF position. 27. Verify that the shift lever cannot be removed from PARK when the ignition key is in the OFF position. 28. Turn the ignition key to the ON position and verify that the shift lever can be removed from PARK. 29. Return the shift lever to the PARK position and verify that the ignition key can be turned to the OFF position and removed without difficulty. If the key can be removed without difficulty, proceed to Step 33. If the key cannot be removed or requires high effort, proceed to Step 30. 30. Adjust the cable length by pulling the white adjustment tab out from the adjuster body located in the middle of the cable. 31. Move the shift lever from the PARK position to reverse and back to the PARK position and turn the ignition key to the OFF position. 32. Press the white adjustment tab inwards until it locks in place. Verify proper operation by performing Steps 26-29. 33. install the radio assembly. 34. Install the upper steering column cover. 35. Install the lower steering column cover and position the shift lever seal in place. 36. Install the tilt lever. 37. Install the instrument cluster bezel and ignition lock/switch bezel. 38. Install the driver's side knee bolster. 39. Install the driver's side knee bolster cover. 40. Install the left side lower instrument panel insulator. 41. Enable the SIR system. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 00-07-30-018 > Nov > 00 > Shift Lever/Ignition Cylinder - High Effort To Move Technical Service Bulletin # 00-07-30-018 Date: 001101 Shift Lever/Ignition Cylinder - High Effort To Move File In Section: 07 - Transmission/Transaxle Bulletin No.: 00-07-30-018 Date: November, 2000 Subject: High Effort Required to Turn Ignition key and Remove Shift Lever from Park Position (Replace Transmission Shift Control Cable Assembly and Fasteners) Models: 2000 Chevrolet Impala 2000 Pontiac Bonneville with column shift only Condition Some owners of vehicles that have the transmission shift lever mounted on the steering column may comment that they have difficulty removing the transmission shift lever from the park position. In addition, some may also comment that it takes a high amount of effort to rotate or turn the ignition key. Cause The steering column mounted transmission linear shift control cable that attaches to the ignition switch may be too long and may also be routed incorrectly. Correction Replace the steering column mounted transmission linear shift control and cable assembly with a new assembly that has a shorter cable and an adjustment feature. Use the following service procedure for installing and adjusting. For additional information and fastener torque specifications, see the Steering Column sub-section in the Steering section, and the Instrument Panel sub-section in the Body and Accessories section of the appropriate Service Manual. Parts Information IMPALA MODELS BONNEVILLE MODEL Parts are currently available from GMSPO. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 00-07-30-018 > Nov > 00 > Shift Lever/Ignition Cylinder - High Effort To Move > Page 7521 For vehicles repaired under warranty, use the table. Disclaimer Impala Service Procedure 1. Disable the SIR system. 2. Remove the left side lower instrument panel insulator. 3. Remove the lower steering column filler panel. 4. Remove the aluminum knee bolster bracket. 5. Remove the tilt ever. 6. Remove the lower steering column cover. 7. Remove the upper steering column cover. 8. Remove the two nuts attaching the column to the column support and lower the column. Important: The plastic tie bands removed in the next step have to be reinstalled or replaced when servicing the linear shift control cable assembly. Also do not remove the plastic tie bands from the new assembly. 9. Remove (cut) any plastic tie bands that secure or route the cable assembly to the ignition switch. 10. Depress the black tab on the end of the cable and pull the cable out of the backside of the ignition switch/lock cylinder assembly. 11. Disconnect the transmission shift cable and the brake/transmission shift interlock red from tee linear shift control cable assembly. 12. Remove the shift lever retaining screw. Discard the screw and remove the lever. 13. Remove the three screws that attach the linear shift control cable assembly to the steering column and discard the three screws. 14. Remove the linear shift control cable assembly from the steering column and vehicle. 15. Install the new linear shift control cable assembly, P/N 26064241, on the steering column secure with three new screws, P/N 26020231. 16. Install the shift lever and secure with new screw, P/N 26086313. 17. Connect the transmission shift cable and the brake/transmission shift interlock rod to the linear shift control cable assembly. 18. Insert the cable into the backside of the ignition switch/lock cylinder assembly and lock in place. 19. Raise the steering column to the column support and secure with two nuts. 20. Verify cable routing for clearance with brake switches. 21. Move the shift lever from PARK to reverse and back to the PARK position and turn the ignition key to the OFF position. 22. Verify that shift lever cannot be removed from PARK when the ignition key is in the OFF position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 00-07-30-018 > Nov > 00 > Shift Lever/Ignition Cylinder - High Effort To Move > Page 7522 23. Turn the ignition key to the ON position and verify that the shift lever can be removed from PARK. 24. Return the shift lever to the PARK position and verify that the ignition key can be turned to the OFF position and removed without difficulty. If key can be removed without difficulty, proceed to Step 28. If the key cannot be removed or requires high effort, proceed to Step 25. 25. Adjust the cable length by moving the white adjustment tab outwards from the adjuster body located in the middle of the cable. 26. Move the shift lever from PARK to reverse and back to the PARK position and turn the ignition key to the OFF position. 27. Press the white adjustment tab inwards until it locks in place. Verify proper operation by performing Steps 21-24. 28. Install the upper steering column cover. 29. Install the lower steering column cover and position the shift lever seal in place. 30. Install the tilt lever. 31. Install the aluminum knee bolster bracket. 32. Install the lower steering column filler panel. 33. Install the left side lower instrument panel filler. 34. Enable the SIR system. Bonneville Service Procedure 1. Disable SIR system. 2. Remove left side lower instrument panel insulator. 3. Remove the driver's side knee bolster cover. 4. Remove the driver's side knee bolster. 5. Remove the ignition lock/switch bezel. 6. Remove the instrument cluster bezel. 7. Remove the tilt lever. 8. Remove the lower steering column cover. 9. Remove the upper steering column cover. 10. Remove two nuts and loosen two bolts to lower steering column for access to linear shift control cable assembly. Important: The plastic tie bands removed in the next step have to be reinstalled or replaced when servicing the linear shift control cable assembly. Also, do not remove the plastic tie bands from the new assembly. 11. Remove (cut) any plastic tie bands that secure or route the cable assembly to the ignition switch. 12. Disconnect the transmission shift cable and the brake/transmission safety interlock rod from the linear shift control cable assembly. 13. Remove the shift lever retaining screw. Discard the screw and remove the shift lever. 14. Remove the three screws attaching the linear shift control cable assembly to the steering column and discard the screws. 15. Remove the radio assembly. 16. Remove the ignition lock/switch assembly from the instrument panel. 17. Depress the black tab on the end of the cable and pull the cable out of the backside of the ignition lock/switch assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 00-07-30-018 > Nov > 00 > Shift Lever/Ignition Cylinder - High Effort To Move > Page 7523 18. Remove the linear shift control cable assembly from the steering column and vehicle. 19. Install the new linear shift control cable assembly, P/N 26089928, on the steering column and secure with three new screws, P/N 26071469. 20. Install the shift lever and secure with new screw, P/N 26086318. 21. Connect the transmission shift cable and the brake/transmission shift interlock rod to the linear shift control cable assembly. 22. Insert the cable into the backside of the ignition lock/switch assembly and lock into place. 23. Install the ignition lock/switch assembly in the instrument panel. 24. Raise the steering column and install and the tighten nuts and bolts. 25. Verify cable routing for clearance with brake switches. 26. Move the shift lever from the PARK position to reverse and back to the PARK position and turn the ignition key to the OFF position. 27. Verify that the shift lever cannot be removed from PARK when the ignition key is in the OFF position. 28. Turn the ignition key to the ON position and verify that the shift lever can be removed from PARK. 29. Return the shift lever to the PARK position and verify that the ignition key can be turned to the OFF position and removed without difficulty. If the key can be removed without difficulty, proceed to Step 33. If the key cannot be removed or requires high effort, proceed to Step 30. 30. Adjust the cable length by pulling the white adjustment tab out from the adjuster body located in the middle of the cable. 31. Move the shift lever from the PARK position to reverse and back to the PARK position and turn the ignition key to the OFF position. 32. Press the white adjustment tab inwards until it locks in place. Verify proper operation by performing Steps 26-29. 33. install the radio assembly. 34. Install the upper steering column cover. 35. Install the lower steering column cover and position the shift lever seal in place. 36. Install the tilt lever. 37. Install the instrument cluster bezel and ignition lock/switch bezel. 38. Install the driver's side knee bolster. 39. Install the driver's side knee bolster cover. 40. Install the left side lower instrument panel insulator. 41. Enable the SIR system. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 7524 Shift Cable: Specifications Automatic Transmission Range Selector Cable Bracket Bolts 18 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 7525 Shift Cable: Adjustments Caution: Refer to Automatic Transaxle Range Selector Cable Caution in Service Precautions. Notice: Adjust the automatic transaxle range selector cable while the transaxle and while the gear selector are in the Neutral position only. Failure to do so may cause misadjustment. 1. Set the parking brake. 2. Block the wheels. 3. Disconnect the shift cables at both ends with the system in Neutral. Notice: Do NOT attempt to separate the metal couplings. Replace both cable pieces if the metal couplings are separated. Both of the cable sections will be damaged if the two metal couplings are disconnected. 4. Push up to the adjustment position to release the adjuster until the cable housings separate. 5. Depress the adjuster clip once. This mobilizes the adjuster housing toward the transaxle end fitting. 6. Line up the end fittings so they slide together until you feel the parts cam together and lock. 7. Depress the adjuster clip completely. This locks the cable into its adjusted service position. 8. Pull the conduit in the opposite direction to assure full system adjustment of the shift cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 7526 Important: The horseshoe clip with the tab is flush when fully engaged. 9. Ensure the conduit is fully engaged. 10. The horseshoe clip with the tab is not flush when not fully engaged. 11. Install the shift cable to the retainers. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission Range Selector Cable Replacement Shift Cable: Service and Repair Automatic Transmission Range Selector Cable Replacement New Cable Installation Only Caution: Refer to Automatic Transaxle Range Selector Cable Caution in Service Precautions. 1. Set the parking brake. 2. Block the wheels. 3. Place the transaxle in the Neutral position. 4. Place the shift control in the Neutral position. 5. Connect each cable section to the following before connecting the two cable sections: - To the automatic transaxle range selector lever and shift cable bracket. - To the column or the console shift control and retainer or wiring harness clip. 6. Insert the metal end fitting of the shift control cable into the transaxle cable end. 7. Use the molded end fittings to push the metal end fitting of the shift control cable and the transaxle cable end together until the metal post snaps into place. 8. Depress the adjuster clip once. This mobilizes the adjuster housing toward the transaxle end fitting. 9. Line up the end fittings so they slide together until you feel the parts cam together and lock. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission Range Selector Cable Replacement > Page 7529 10. Depress the adjuster clip completely. This locks the cable into its adjusted service position. 11. Pull the conduit in the opposite direction to assure full system adjustment of the shift cable. Important: The horseshoe clip with the tab, is flush when fully engaged. 12. Ensure the conduit is fully engaged. 13. The selector cable is not fully engaged if the horseshoe clip is not flush with the tab. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission Range Selector Cable Replacement > Page 7530 14. Install the shift cable to the retainers. At Manual Shaft Removal Procedure Caution: Refer to Automatic Transaxle Range Selector Cable Caution in Service Precautions. 1. Remove the throttle body air inlet duct. Refer to Air Cleaner Assembly Replacement in Powertrain Management. 2. Remove the automatic transaxle range selector cable from the retainers. 3. Remove the automatic transaxle range selector cable from the automatic transaxle range selector lever. 4. Remove the automatic transaxle range selector cable from the automatic transaxle range selector cable bracket. 5. Remove the automatic transaxle range selector cable from the shift control. Refer to Automatic Transmission Range Selector Cable Replacement (New Cable Installation Only) or Automatic Transmission Range Selector Cable Replacement (At Manual Shaft) or Automatic Transmission Range Selector Cable Replacement (At Console Shift Control) or Automatic Transmission Range Selector Cable Replacement (At Column Shift Control). 6. Pull the automatic transaxle range selector cable through the dash from the engine compartment side. Installation Procedure Caution: Refer to Automatic Transaxle Range Selector Cable Caution in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission Range Selector Cable Replacement > Page 7531 1. Insert the automatic transaxle range selector cable through the dash from the engine compartment side. 2. Install the automatic transaxle range selector cable to the automatic transaxle range selector cable bracket. 3. Install the automatic transaxle range selector cable to the automatic transaxle range selector lever. 4. Install the automatic transaxle range selector cable to the retainers. 5. Install the automatic transaxle range selector cable to the shift control. Refer to Automatic Transmission Range Selector Cable Replacement (New Cable Installation Only) or Automatic Transmission Range Selector Cable Replacement (At Manual Shaft) or Automatic Transmission Range Selector Cable Replacement (At Console Shift Control) or Automatic Transmission Range Selector Cable Replacement (At Column Shift Control). 6. Adjust the automatic transaxle range selector cable. Refer to Automatic Transmission Range Selector Cable Adjustment. 7. Install the throttle body air inlet duct. Refer to Air Cleaner Assembly Replacement in Powertrain Management. At Console Shift Control Removal Procedure Caution: Refer to Automatic Transaxle Range Selector Cable Caution in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission Range Selector Cable Replacement > Page 7532 1. Remove the automatic transaxle range selector cable from wiring harness retainers in the engine compartment. 2. Remove the console. Refer to Console Replacement - Front Floor (Impala) or Console Replacement - Front Floor (Monte Carlo) in Instrument Panel, Gauges and Warning Indicators. 3. Pull the carpet back to expose the automatic transaxle range selector cable. Refer to Carpet Replacement - Front in Body and Frame. 4. Remove the automatic transaxle range selector cable from the retainers in the passenger compartment. 5. Disengage the automatic transaxle range selector cable retainer to the console shift control. 6. Remove the automatic transaxle range selector cable retainer from the console shift control. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission Range Selector Cable Replacement > Page 7533 7. Remove the automatic transaxle range selector cable from the console shift control. 8. Remove the automatic transaxle range selector cable through the hole in the cowl. 9. Remove the automatic transaxle range selector cable from the manual shaft. Refer to Automatic Transmission Range Selector Cable Replacement (New Cable Installation Only) or Automatic Transmission Range Selector Cable Replacement (At Manual Shaft) or Automatic Transmission Range Selector Cable Replacement (At Console Shift Control) or Automatic Transmission Range Selector Cable Replacement (At Column Shift Control). Installation Procedure Caution: Refer to Automatic Transaxle Range Selector Cable Caution in Service Precautions. 1. Properly route and position the automatic transaxle range selector cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission Range Selector Cable Replacement > Page 7534 2. Install the automatic transaxle range selector cable through the hole in the cowl. 3. Install the automatic transaxle range selector cable to the manual shaft. Refer to Automatic Transmission Range Selector Cable Replacement (New Cable Installation Only) or Automatic Transmission Range Selector Cable Replacement (At Manual Shaft) or Automatic Transmission Range Selector Cable Replacement (At Console Shift Control) or Automatic Transmission Range Selector Cable Replacement (At Column Shift Control). 4. Install the automatic transaxle range selector cable through the console shift control bracket. 5. Install the automatic transaxle range selector cable to the console shift control. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission Range Selector Cable Replacement > Page 7535 6. Engage the automatic transaxle range selector cable retainer to the console shift control. 7. Install the automatic transaxle range selector cable to the retainers in the passenger compartment. 8. Install the carpet into position. Refer to Carpet Replacement - Front in Body and Frame. 9. Install the console. Refer to Console Replacement - Front Floor (Impala) or Console Replacement Front Floor (Monte Carlo) in Instrument Panel, Gauges and Warning Indicators. 10. Install the automatic transaxle range selector cable to the wiring harness retainers in the engine compartment. 11. Adjust the automatic transaxle range selector cable. Refer to Automatic Transmission Range Selector Cable Adjustment. At Column Shift Control Removal Procedure Caution: Refer to Automatic Transaxle Range Selector Cable Caution in Service Precautions. 1. Remove the automatic transaxle range selector cable retainer from the stud in the engine compartment. 2. Remove the steering column trim panel. Refer to Steering Column Filler Replacement in Instrument Panel, Gauges and Warning Indicators. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission Range Selector Cable Replacement > Page 7536 3. Remove the automatic transaxle range selector cable from the shift control lever. 4. Remove the automatic transaxle range selector cable from the manual shaft. Refer to Automatic Transmission Range Selector Cable Replacement (New Cable Installation Only) or Automatic Transmission Range Selector Cable Replacement (At Manual Shaft) or Automatic Transmission Range Selector Cable Replacement (At Console Shift Control) or Automatic Transmission Range Selector Cable Replacement (At Column Shift Control). 5. Remove the automatic transaxle range selector cable through the hole in the dash. Installation Procedure Caution: Refer to Automatic Transaxle Range Selector Cable Caution in Service Precautions. 1. Install the automatic transaxle range selector cable through the hole in the dash. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission Range Selector Cable Replacement > Page 7537 2. Properly route and position the automatic transaxle range selector cable. 3. Install the automatic transaxle range selector cable to the manual shaft. Refer to Automatic Transmission Range Selector Cable Replacement (New Cable Installation Only) or Automatic Transmission Range Selector Cable Replacement (At Manual Shaft) or Automatic Transmission Range Selector Cable Replacement (At Console Shift Control) or Automatic Transmission Range Selector Cable Replacement (At Column Shift Control). 4. Install the automatic transaxle range selector cable to the shift control lever. 5. Install the steering column trim panel. Refer to Steering Column Filler Replacement in Instrument Panel, Gauges and Warning Indicators. 6. Install the automatic transaxle range selector cable retainer to the stud in the engine compartment. 7. Adjust the transaxle side automatic transaxle range selector cable. Refer to Automatic Transmission Range Selector Cable Adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission Range Selector Cable Replacement > Page 7538 Shift Cable: Service and Repair Automatic Transmission Range Selector Cable Bracket Replacement Removal Procedure 1. Remove the throttle body air inlet duct. Refer to Powertrain Management. 2. Remove the automatic transaxle range selector cable from the automatic transaxle range selector [ever. 3. Remove the clip then release the cable from the range selector cable bracket. 4. Remove the automatic transaxle range selector cable bracket bolts. 5. Remove the automatic transaxle range selector cable bracket from the automatic transaxle. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission Range Selector Cable Replacement > Page 7539 1. Install the automatic transaxle range selector cable bracket to the automatic transaxle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the automatic transaxle range selector cable bracket bolts. - Tighten the automatic transaxle range selector cable bracket bolts to 25 Nm (18 ft. lbs.). 3. Install the automatic transaxle range selector cable to the bracket. 4. Install the retaining clip. 5. Install the automatic transaxle range selector cable to the automatic transaxle range selector lever. 6. Adjust the automatic transaxle range selector cable if necessary. Refer to Automatic Transmission Range Selector Cable Adjustment 7. Install the throttle body air inlet duct. Refer to Powertrain Management. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: Customer Interest A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 7548 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 7549 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: All Technical Service Bulletins A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 7555 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 7556 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information Torque Converter: Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information > Page 7561 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 7562 Torque Converter: Specifications Automatic Transmission Torque Converter Bolts 47 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 7563 Torque Converter: Testing and Inspection For testing of this component and the system that it is a part of, refer to Automatic Transmission/Transaxle Testing and Inspection. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Torque Converter Check Valve: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 7568 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 7572 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 7573 Torque Converter Clutch Solenoid: Service and Repair Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the torque converter clutch PWM solenoid (334). Installation Procedure 1. Install the torque converter clutch PWM solenoid (334). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Cover > Component Information > Specifications Torque Converter Cover: Specifications Automatic Transmission Torque Converter Cover Bolts 89 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Cover > Component Information > Service and Repair > Torque Converter Cover Replacement Torque Converter Cover: Service and Repair Torque Converter Cover Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the torque converter cover bolts. 3. Remove the torque converter covers from the transaxle. Installation Procedure 1. Install the torque converter covers. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the torque converter cover bolts. - Tighten the torque converter cover bolts to 10 Nm (89 inch lbs.). 3. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Cover > Component Information > Service and Repair > Torque Converter Cover Replacement > Page 7579 Torque Converter Cover: Service and Repair Flywheel to Torque Converter Bolts Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the torque converter covers. Refer to Torque Converter Cover Replacement. 3. Remove the flywheel to torque converter bolts. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the flywheel to torque converter bolts. - Tighten the flywheel to torque converter bolts to 63 Nm (47 ft. lbs.). 2. Install the torque converter covers. Refer to Torque Converter Cover Replacement 3. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7584 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7585 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7586 Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7587 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7588 Transmission Cooler: Technical Service Bulletins A/T - Oil Cooler Flushing Frequently Asked Questions File In Section: 07 - Transmission/Transaxle Bulletin No.: 03-07-30-027 Date: June, 2003 INFORMATION Subject: Most Frequently Asked Questions and Answers for J 45096 TransFlow Transmission Oil Cooling System Flushing Machine Models: 2004 and Prior Passenger Cars and Light Duty Trucks with Automatic Transmission/Transaxle 2004 and Prior HUMMER H2 This bulletin is issued to help answer the most frequently asked questions and concerns about essential tool J 45096. Q: Why doesn't the machine work below 18°C (65°F)? A: The flow characteristics of ATF at temperatures below 18°C (65°F) does not provide accurate flow test results with the electronics used in the J 45096. Q: Why didn't the unit come with a tank heater? A: The vast majority of dealerships do not require a heater to keep the ATF above 18°C (65°F). As a result, the heater was deleted as a cost-savings measure. A tank heater, J 45096-10, is currently available from Kent-Moore if your dealership requires it. Refer to Corporate Bulletin Number 03-07-30-002A for suggestions on warming the ATF without using a heater blanket. Q: Why does the machine fail new oil coolers? A: Several reasons have been found. The most likely reason is the air pressure at the air hose connected to the J 45096 is less than 586 kPa (85 psi). Other reasons include a twisted hose inside the J 45096 at the bulkhead as a result of the nut turning when the waste or supply hose was installed, the internal pressure regulator was improperly set at the factory or a problem with the cooler lines on the vehicle. Perform the J 45096 self-test as described on pages 9 and 10 of the Operation Manual. If a problem is still detected, refer to Troubleshooting on page 19 of the Operation Manual. If a problem still persists, contact Kent-Moore Customer Service at 1-800-345-2233. Q: What is the difference between steel and aluminum oil coolers? A: The aluminum oil cooler tube is slightly thinner in construction than the steel oil cooler tube, which affects the oil flow rate. The fitting that is protruding out of the radiator tank easily identifies the aluminum oil cooler. Refer to the Quick Reference card provided with the J 45096 in order to identify the proper flow rate for the aluminum oil cooler. Q: Why can't I use TransFlow for Allison transmission cooling Systems? A: Validation of TransFlow is currently under development for light duty trucks equipped with the Allison automatic transmission. TransFlow is based on the existing MINIMUM flow rate specification through the transmission oil cooling system. The Allison transmission oil cooling system only has MAXIMUM oil flow rates specified and J 45096 does not have the capability to test the transmission oil cooling system at the maximum oil flow rate specification. Q: Why doesn't GM publish a specification for auxiliary transmission oil coolers? A: The auxiliary oil cooler used with GM vehicles does not contain an internal turbulator plate like the radiator tank oil cooler does. Therefore, there is no internal restriction that would affect the flow rate through the oil cooling system so a specification for auxiliary oil cooler is not required. Keep in mind, kinks and damage to the auxiliary cooler and lines can affect the flow rate through the system. Q: Why did GM drop the labor time for transmission repairs? A: The labor for flushing and flow testing the transmission oil cooling system is included with the R&R; labor of the "K" labor operations that require transmission removal. The time required to use the J 45096 to perform the flush and flow test is much less than that of the J 35944-A. The warranty labor savings allowed GM to provide the J 45096 at no cost to dealerships. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7589 Q: Why didn't the machine come with the adapters to hook up to the car? A: The J 45096 was designed to use the previously released essential cooler line adapters for the J 35944-A. All adapters are listed on page 17 of the Operation Manual and can be ordered from Kent-Moore at 1-800-345-2233. Q: How do I connect the J 45096 to a Catera, Prizm or a Vibe? A: These vehicles, along with many other models, only require barbed fittings to connect to the rubber cooler hose. These fittings are commercially available and already found in many shops. Q: Why didn't I receive an Operation Manual with the machine? A: The Operation Manual was packaged in the upper portion of the shipping carton. If the shipping carton was lifted off the base without opening the top of the carton, the Operation Manual could have been discarded with the carton. Replacement Operation Manual packages can be obtained from Kent-Moore Customer Service at 1-800-345-2233. Q: Why can't I re-use the transmission fluid I use for flushing? A: The very fine metal and clutch material debris from the transmission failure in the ATF causes failures with the hall effect speed sensors that are used to measure the flow rate. To avoid costly repairs, expensive filters, regular maintenance and problems caused by a partially restricted filter, the filter was not included. Q: What do I do if I need service on my machine? A: Call Kent-Moore Customer Service at 1-800-345-2233. The J 45096 has a one-year warranty. Q: Can I flush and flow engine oil coolers? A: The engine oil cooler flow rates, the appropriate adapters and an acceptable procedure are currently under development. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7590 Transmission Cooler: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 7591 Transmission Cooler: Specifications Automatic Transmission Auxiliary Oil Cooler Bolts 18 ft.lb Automatic Transmission Auxiliary Oil Cooler Pipe Fittings 17 ft.lb Automatic Transmission Auxiliary Oil Cooler Nuts 97 in.lb Oil Cooler Quick Connector 28 ft.lb Oil Cooler Quick Connector with Checkball 28 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Automatic Transmission Oil Cooler Flushing Transmission Cooler: Service and Repair Automatic Transmission Oil Cooler Flushing Oil Cooler Flushing Procedure - Tool Required J 35944-A Oil Cooler and Line Flusher Caution: Air supply must be equipped with a water and oil filter. This air supply must not exceed 825 kPa (120 psi). Excess air pressure may rupture the flushing cooler, causing personal injury. 1. Remove the fill cap on the J 35944-A. 2. Use 0.6 liters (20 ounces) of flushing solution to fill the J 35944-A. Follow the manufacturer's suggested procedures for the handling of the solution. Do NOT overfill. 3. Replace the cap on the J 35944-A. 4. Pressurize the J 35944-A to 550 - 700 kPa (80 - 100 psi). 5. Connect a discharge hose to the transaxle end of the oil cooler pipe that feeds the BOTTOM fitting of the oil cooler and clip the discharge hose to the oil drain container. 6. Connect the feed hose from the J 35944-A to the remaining oil cooler pipe. 7. Ensure the J 35944-A water valve is in the OFF position. 8. Connect the water supply to the J 35944-A. 9. Turn the water supply on. Caution: If water does not flow through the cooler, do not continue with the flushing procedure. The cooling system may be plugged and excess pressure may rupture the cooler, causing personal injury. Replace the cooler pipe or the cooler if necessary. 10. Turn the water valve to the ON position for about 10 seconds to flush the transaxle fluid. 11. Close the water valve. 12. Clip the discharge hose to the 5 gallon pail. 13. Cover the pail with a shop towel to prevent splashing. 14. Turn the water valve to the ON position. 15. Depress the trigger to mix the flushing solution into the water flow. 16. Use the bale clip provided to hold the trigger down. 17. Use water and the solution to flush the cooler for two minutes. 18. Attach the air supply to the air valve located on the J 35944-A for three to five seconds every 15-20 seconds during the flush. This creates a surging action to ensure complete cleaning. 19. Release the trigger. 20. Turn the water valve off. 21. Disconnect both hoses from the oil cooler pipes. 22. Reconnect the hoses to the pipes opposite the initial flush to perform a backflush. 23. Repeat step 15 through step 19. 24. Release the trigger. 25. Allow water to rinse for one minute. 26. Turn the water valve off. 27. Turn the water supply off. 28. Attach the air supply to the air valve. 29. Dry the system out with air until no moisture is seen leaving the discharge hose. 30. Connect the cooler feed pipe to the transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Automatic Transmission Oil Cooler Flushing > Page 7594 31. Reconnect the discharge hose to the cooler return pipe. 32. Clip the discharge hose to the oil drain container. 33. Start the engine after filling the transaxle with fluid. 34. Run the engine for 30 seconds. This removes any residual moisture from the oil cooler. A minimum of 1.9 liters (2 quarts) of fluid should flow during the 30 second period. 35. Perform the following steps if the fluid flow is insufficient: 35.1. Disconnect the feed line at the cooler. 35.2. Observe the flow while the engine is running to check the fluid flow from the transaxle. 35.3. Inspect the transaxle for a possible cause. 35.4. Inspect the cooler pipes if flow from transaxle is insufficient. 35.5. Inspect the fittings if flow from transaxle is insufficient. 35.6. Repeat the cooler flushing procedure. 36. Remove the discharge hose. 37. Connect the cooler pipe. 38. Adjust the fluid level. Refer to Transmission Fluid Checking Procedure. 39. Inspect for fluid leaks. Refer to Fluid Leak Diagnosis. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Automatic Transmission Oil Cooler Flushing > Page 7595 Transmission Cooler: Service and Repair Automatic Transmission Oil Cooler Fitting Replacement Removal Procedure Notice: Allow sufficient clearance around the transaxle oil cooler pipes and around the hoses to prevent damage or wear which may cause fluid loss. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Position a drain pan under the vehicle. 3. Remove the transaxle oil cooler hoses from the transaxle oil cooler fittings. Refer to Automatic Transmission Oil Cooler Pipes Replacement. 4. Remove the transaxle oil cooler fittings (28,29) from the transaxle. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: The correct thread engagement is critical. Cross threaded fittings can achieve proper tightness and still leak. 1. Apply sealant to the transaxle oil cooler fittings (28,29). - For green inlet cooler fitting GM P/N 8651654. - For outlet cooler fittings GM P/N 24202550. - For line pressure plug GM P/N 8654382. 2. Install the transaxle oil cooler fittings (28,29) to the transaxle. - Tighten the transaxle oil cooler fittings (28,29) to 38 Nm (28 ft. lbs.). 3. Install the transaxle oil cooler hoses to the transaxle oil cooler fittings. Refer to Automatic Transmission Oil Cooler Pipes Replacement. 4. Lower the vehicle. Notice: Do NOT overfill the transaxle. The overfilling of the transaxle causes foaming, loss of fluid, shift complaints, and possible damage to the transaxle. 5. Adjust the fluid level. Refer to Transmission Fluid Checking Procedure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Automatic Transmission Oil Cooler Flushing > Page 7596 6. Inspect for fluid leaks. Refer to Fluid Leak Diagnosis. 7. Remove the drain pan from under the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications Transmission Mount: Specifications Automatic Transmission Mount Bracket Bolts 70 ft.lb Automatic Transmission Mount to Automatic Transmission Bracket Nuts 35 ft.lb Automatic Transmission Mount to Frame Nuts 35 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Automatic Transmission Mount Inspection Transmission Mount: Service and Repair Automatic Transmission Mount Inspection Notice: In order to avoid oil pan damage and possible engine failure, insert a block of wood that spans the width of the oil pan bottom between the oil pan and the jack support. 1. Raise and support the vehicle. Refer to Vehicle Lifting. Important: Before replacing any transmission/transaxle mount due to suspected fluid loss, verify that the source of the fluid is the transmission/transaxle mount, not the engine, transmission/transaxle or accessories. 2. Raise the transmission/transaxle in order to remove the weight from the transmission/transaxle mount and create slight tension in the rubber. 3. Observe the transmission/transaxle mount while raising the transmission/transaxle. Replace the transmission/transaxle mount if the transmission/transaxle mount exhibits any of the following conditions: The hard rubber surface is covered with heat check cracks. - The rubber is separated from the metal plate of the transmission/transaxle mount. - The rubber is split through the center of the transmission/transaxle mount. - If the transaxle needs replaced. Refer to Automatic Transmission Mount Replacement 4. If there is movement between the metal plate of the transmission/transaxle mount and its attaching points, lower the transmission/transaxle on the transmission/transaxle mount. Tighten the bolts or nuts attaching the transmission/transaxle mount to the frame or transmission/transaxle mount bracket. Refer to Automatic Transmission Mount Replacement. 5. lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Automatic Transmission Mount Inspection > Page 7602 Transmission Mount: Service and Repair Automatic Transmission Mount Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the left tire and wheel assembly. 3. Remove left inner splash shield. 4. Position a transmission jack under the transaxle. 5. Remove the transaxle mount upper nuts from the transaxle bracket. 6. Carefully raise the transaxle assembly. 7. Remove the transaxle mount lower nuts from the frame. 8. Remove the transaxle mount from the frame. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Automatic Transmission Mount Inspection > Page 7603 1. Position the transaxle mount to the frame. Notice: Refer to Fastener Notice in Service Precautions 2. Install the transaxle mount lower nuts to the frame. - Tighten the transaxle mount lower nuts to 63 Nm (46 ft. lbs.). 3. Lower the transaxle so the transaxle mount studs install into the transaxle bracket. Notice: Refer to Fastener Notice in Service Precautions 4. Install the transaxle mount upper nuts to the transaxle mount. - Tighten the transaxle mount upper nuts to 47 Nm (35 ft. lbs.). 5. Remove the transmission jack from the transaxle. 6. Install left inner splash shield. 7. Install the left wheel and tire assembly. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Automatic Transmission Mount Inspection > Page 7604 Transmission Mount: Service and Repair Automatic Transmission Brace Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Remove the transaxle brace bolts. 4. Remove the transaxle brace. Installation Procedure 1. Install the transaxle brace. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transaxle brace bolts to the transaxle. - Tighten the transaxle brace bolts to the transaxle to 43 Nm (32 ft. lbs.). 3. Install the transaxle brace bolts to the engine. - Tighten the transaxle brace bolts to the engine to 63 Nm (46 ft. lbs.). 4. Install the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 5. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Automatic Transmission Mount Inspection > Page 7605 Transmission Mount: Service and Repair Automatic Transmission Mount Bracket Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Remove the left engine splash shield. Refer to Splash Shield Replacement - Engine (Left) in Body and Frame. 4. Support the transaxle. 5. Remove the transaxle bracket to transaxle mount upper nuts. 6. Remove the transaxle bracket to transaxle bolts. 7. Remove the transaxle bracket. Installation Procedure 1. Position the transaxle bracket to the transaxle. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Automatic Transmission Mount Inspection > Page 7606 2. Install the transaxle bracket bolts. - Tighten the transaxle bracket bolts to 95 Nm (70 ft. lbs.). 3. Remove the support from the transaxle. 4. Install the transaxle bracket to the transaxle mount upper nuts. - Tighten the transaxle mount upper nuts to 47 Nm (35 ft.lbs.). 5. Install the left engine splash shield. Refer to Splash Shield Replacement - Engine (Left) in Body and Frame. 6. Install the left front tire and wheel. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment 7. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Inside the automatic transaxle Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 7610 Park Neutral Position (PNP) Switch C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Specifications Transmission Pressure Test Port: Specifications Oil Pressure Test Hole Plug ................................................................................................................ ................................................................... 106 Lb In Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Specifications > Page 7614 Transmission Pressure Test Port: Service and Repair Removal Procedure 1. Remove the throttle body air inlet duct. Refer to Powertrain Management. 2. Remove the line pressure pipe plug (38) from the automatic transmission. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the line pressure pipe plug (38). - Tighten the line pressure pipe plug (38) to 12 Nm (106 inch lbs.). 2. Install the throttle body air inlet duct. Refer to Powertrain Management. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 7618 Transmission Speed Sensor: Service and Repair Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the input speed sensor clip (441) from the case cover. 4. Remove the input speed sensor (440) from the case cover. 5. Inspect the input speed sensor (440) for the following conditions: - Damaged or missing magnet - Damaged housing - Bent or missing electrical terminals - Damaged speed sensor clip (441) Installation Procedure 1. Install the input speed sensor (440) into the case cover. 2. Install the input speed sensor clip (441) into the case cover. 3. Connect the transaxle wiring harness. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 7619 4. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Automatic Transaxle Fluid Temperature (TFT) Sensor Transmission Temperature Sensor/Switch: Locations Automatic Transaxle Fluid Temperature (TFT) Sensor Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Automatic Transaxle Fluid Temperature (TFT) Sensor > Page 7624 Transmission Temperature Sensor/Switch: Locations Transaxle Fluid Temperature (TFT) Sensor Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 7625 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 7626 Transmission Temperature Sensor/Switch: Service and Repair Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement 2. Disconnect the wiring harness assembly from the fluid temperature sensor (391). 3. Remove the fluid temperature sensor (391). Installation Procedure 1. Install the fluid temperature sensor (391). 2. Connect the wiring harness assembly to the with fluid temperature sensor (391). 3. Install the case side cover. Refer to Case Side Cover Replacement Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Turbine Shaft, A/T > Component Information > Technical Service Bulletins > Customer Interest for Turbine Shaft: > 00-07-30-007A > Feb > 02 > A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL Turbine Shaft: Customer Interest A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL File In Section: 07 - Transmission/Transaxle Bulletin No.: 00-07-30-007A Date: February, 2002 TECHNICAL Subject: Whine Noise In Park Or Neutral, Service Engine Soon or Service Vehicle Soon Lamp Illuminates (Replace Drive Sprocket Support Bearing) Models: 1999-2000 Buick LeSabre, Park Avenue/Ultra, Regal, Riviera 1999-2000 Chevrolet Lumina, Monte Carlo, Venture 2000 Chevrolet Impala 1999 Oldsmobile Eighty Eight 1999-2000 Oldsmobile Intrigue, Silhouette 1999-2000 Pontiac Bonneville, Grand Prix, Montana with 3.4L, 3.5L or 3.8L Engine (VINs E, H, K, 1-- RPOs LA1, LX5, L36, L67) and Hydra-Matic 4T65-E Transaxle/Transmission (RPOs MN3, MN7, M15) This bulletin is being revised to add the Chevrolet Impala to the models affected. Please discard Corporate Bulletin Number 00-07-30-007 (Section 07 - Transmission/Transaxle). Condition Some owners of the listed models equipped with a Hydra-Matic 4T65-E transaxle with a Julian Date prior to 0045 may comment on a whine noise in PARK and/or NEUTRAL or a Service Engine Soon or Service Vehicle Soon lamp that is illuminated. Upon investigation, a DTC P0741 or P0742 may be found. Cause The above condition may be due to drive sprocket support bearing fluting and/or bearing failure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Turbine Shaft, A/T > Component Information > Technical Service Bulletins > Customer Interest for Turbine Shaft: > 00-07-30-007A > Feb > 02 > A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL > Page 7635 Correction Replace the drive sprocket support bearing. Inspect the channel plate and drive sprocket for any abnormal wear, Turbine shaft for cut seals and/or nicks, and chain for excessive play due to failed bearings. Important: When installing the new bearing, the part number MUST be visible (facing upward). Before installing the drive sprocket, lubricate the bearing assembly with J 36850 assembly lubricant. Refer to the 4T65-E Unit Repair Section for the installation procedure. Service Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Turbine Shaft, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Turbine Shaft: > 00-07-30-007A > Feb > 02 > A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL Turbine Shaft: All Technical Service Bulletins A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL File In Section: 07 - Transmission/Transaxle Bulletin No.: 00-07-30-007A Date: February, 2002 TECHNICAL Subject: Whine Noise In Park Or Neutral, Service Engine Soon or Service Vehicle Soon Lamp Illuminates (Replace Drive Sprocket Support Bearing) Models: 1999-2000 Buick LeSabre, Park Avenue/Ultra, Regal, Riviera 1999-2000 Chevrolet Lumina, Monte Carlo, Venture 2000 Chevrolet Impala 1999 Oldsmobile Eighty Eight 1999-2000 Oldsmobile Intrigue, Silhouette 1999-2000 Pontiac Bonneville, Grand Prix, Montana with 3.4L, 3.5L or 3.8L Engine (VINs E, H, K, 1-- RPOs LA1, LX5, L36, L67) and Hydra-Matic 4T65-E Transaxle/Transmission (RPOs MN3, MN7, M15) This bulletin is being revised to add the Chevrolet Impala to the models affected. Please discard Corporate Bulletin Number 00-07-30-007 (Section 07 - Transmission/Transaxle). Condition Some owners of the listed models equipped with a Hydra-Matic 4T65-E transaxle with a Julian Date prior to 0045 may comment on a whine noise in PARK and/or NEUTRAL or a Service Engine Soon or Service Vehicle Soon lamp that is illuminated. Upon investigation, a DTC P0741 or P0742 may be found. Cause The above condition may be due to drive sprocket support bearing fluting and/or bearing failure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Turbine Shaft, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Turbine Shaft: > 00-07-30-007A > Feb > 02 > A/T - 4T65E, MIL ON/Whine Noise In PARK/NEUTRAL > Page 7641 Correction Replace the drive sprocket support bearing. Inspect the channel plate and drive sprocket for any abnormal wear, Turbine shaft for cut seals and/or nicks, and chain for excessive play due to failed bearings. Important: When installing the new bearing, the part number MUST be visible (facing upward). Before installing the drive sprocket, lubricate the bearing assembly with J 36850 assembly lubricant. Refer to the 4T65-E Unit Repair Section for the installation procedure. Service Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips Valve Body: Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips > Page 7646 Valve Body: Technical Service Bulletins A/T - 4T65-E Spacer Plate/Gasket Service File In Section: 07 - Transmission/Transaxle Bulletin No.: 02-07-30-014A Date: July, 2002 INFORMATION Subject: Servicing 4T65-E Transaxle Spacer Plate and Gaskets Models: 1997-1999 Buick Riviera 1997-2002 Buick Park Avenue 1998-2002 Buick LeSabre 1999-2002 Buick Regal 2000-2002 Buick Century 2002 Buick Rendezvous 1997-2001 Chevrolet Lumina 1997-2002 Chevrolet Monte Carlo 1999-2002 Chevrolet Venture 2000-2002 Chevrolet Impala 1997-1999 Oldsmobile Eighty Eight 1997-2002 Oldsmobile Silhouette 1998-2002 Oldsmobile Intrigue 2001-2002 Oldsmobile Aurora (3.5L) 1997-2002 Pontiac Bonneville, Grand Prix 1999-2001 Pontiac Trans Sport/Montana 2001-2002 Pontiac Aztek with 4T65-E Transaxle (RPOs MN3, MN7, M15, M76). This bulletin is being revised to add models (the Buick Rendezvous, Chevrolet Impala and Pontiac Aztek) Please discard Corporate Bulletin Number 02-07-30-014 (Section 07-Transmission/Transaxle). Beginning February 1, 2002, all 4T65-E transaxles will use a bonded spacer plate and gasket assembly (396). The new bonded spacer plate and gasket assembly may be used in all past model 4T65E transaxles. Notice: Do not attempt to remove the gaskets from a bonded spacer plate. Transmission damage could result. To service the spacer plate for all 4T65-E transaxles produced beginning with Feb. 1, 2002, the vehicle must be serviced with the bonded spacer plate and gasket assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips > Page 7647 For those 4T65-E transaxles produced prior to Feb 1, 2002, the spacer plate gaskets (369 & 371) can be serviced. Spacer plate gaskets can be ordered and serviced individually. However, the spacer plate cannot be ordered/serviced individually. A new bonded spacer plate and gasket assembly must be installed when a spacer plate is called for during maintenance or service. DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 7648 Valve Body: Specifications Valve Body to Case 106 in.lb Valve Body to Case 106 in.lb Valve Body to Case Cover 106 in.lb Valve Body to Case Cover 106 in.lb Valve Body to Case Cover (Torx) 106 in.lb Valve Body to Driven Sprocket Support 18 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 7649 Valve Body: Testing and Inspection For testing of this component and the system that it is a part of, refer to Automatic Transmission/Transaxle Testing and Inspection. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Control Valve Body Replacement Valve Body: Service and Repair Control Valve Body Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Remove the oil pump. Refer to Oil Pan Replacement 3. Remove the valve body bolts (374-381,384). Important: Carefully remove the valve body or the ball check valves (382,373) will fall out. 4. Remove the valve body (300) while keeping the spacer plate (370) with the transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Control Valve Body Replacement > Page 7652 5. Remove the ball check valves (372,373) from the valve body. 6. Remove the spacer plate (370) and gasket. 7. Remove the ball check valves (372) from the case cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Control Valve Body Replacement > Page 7653 8. Inspect each check valve seat in the spacer plate (370) for excessive peening. Place a ball check valve (372) on each seat and use a flashlight in order to look for visible light between the valve and the seat. 9. Inspect all components removed from the transaxle. Refer to Transmission Unit Repair. Installation Procedure - Tools Required J 36850 TRANSJEL TM Notice: Do NOT use any type of grease to retain parts during the assembly of this unit. Using greases other than the recommended assembly lube changes the transaxle fluid characteristics. Using greases other than the recommended assembly lube causes undesirable shift conditions and/or filter clogging. Use TRANSJEL J 36850 or equivalent during the assembly of this unit. 1. Install the ball check valves (372) into the case cover. Use J 36850 in order to retain the ball check valves in their proper locations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Control Valve Body Replacement > Page 7654 2. Install the gasket and the spacer plate (370). 3. Install the ball check valves (372,373) into the valve body. Use the J 36850 to retain the ball check valves in their proper locations. Important: Do NOT use impact type tools on the valve body or on the oil pump. 4. Install the gasket (371) and the valve body (300). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Control Valve Body Replacement > Page 7655 Notice: Refer to Fastener Notice. 5. Install the valve body bolts (374-381,384). - Tighten the M6 x 1.0 x 20 bolt to 8 Nm (70 inch lbs.). - Tighten the M6 x 1.0 x 30 bolt to 12 Nm (106 inch lbs.). - Tighten the M6 x 1.0 x 45 bolt to 12 Nm (106 inch lbs.). - Tighten the M6 x 1.0 x 55 bolt to 11 Nm (97 inch lbs.). - Tighten the M6 x 1.0 x 60 bolt to 12 Nm (106 inch lbs.). - Tighten the M6 x 1.0 x 65 bolt to 12 Nm (106 inch lbs.). - Tighten the M6 x 1.0 x 85 bolt to 11 Nm (97 inch lbs.). - Tighten the M6 x 1.0 x 95 bolt to 16 Nm (12 ft. lbs.). - Tighten the M8 x 1.25 x 90 bolt to 25 Nm (18 ft. lbs.). Important: Do NOT use impact type tools on the valve body or on the oil pump. 6. Install the oil pump. Refer to Oil Pan Replacement. 7. Install the case side cover, Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Control Valve Body Replacement > Page 7656 Valve Body: Service and Repair Oil Weir Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Remove the oil reservoir weir (27). Installation Procedure 1. Install the oil reservoir weir (27). 2. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 02-07-30-022B > Oct > 03 > A/T - MIL/SES Lamp ON/Multiple A/T DTC's Set Wiring Harness: Customer Interest A/T - MIL/SES Lamp ON/Multiple A/T DTC's Set Bulletin No.: 02-07-30-022B Date: October 20, 2003 TECHNICAL Subject: Service Engine Soon (SES) Light On With DTCs P0716 and/or P0717, P0730, P0753, P0758, P1860, P1887, or other Miscellaneous Transmission Trouble Codes Set (Repair Wiring at Transaxle Wiring Pass-thru Connector) Models: 2000-2004 Buick Century, LeSabre, Park Avenue, Regal 2003-2004 Buick Rendezvous 2000-2001 Chevrolet Lumina 2000-2004 Chevrolet Cavalier, Impala, Malibu, Monte Carlo, Venture 2004 Chevrolet Classic 2000-2002 Oldsmobile Intrigue 2000-2003 Oldsmobile Aurora 2000-2004 Oldsmobile Alero, Silhouette 2000-2004 Pontiac Bonneville, Grand Am, Grand Prix, Montana, Sunfire 2001-2004 Pontiac Aztek 2000 Toyota Cavalier with 4T65-E, 4T40-E or 4T45-E Transaxle (RPOs MN3, MN7, M15, M76, MN4, MN5) Supercede: This bulletin is being revised to add the 2004 model year as well as the Chevrolet Classic model. Please discard Corporate Bulletin Number 02-07-30-022A (Section 07-Transmission/Transaxle). Condition Some customers may comment that the Service Engine Soon (SES) indicator is illuminated and that while the light is illuminated, transmission shifts are extremely harsh. Cause These types of conditions may be caused by an intermittent connection at the transaxle 20-way connector to the wiring harness interface. Correction If a DTC was recorded and the Freeze Frame and Failure Records back it up, a problem existed at one time with the wiring and/or the connectors between the transaxle and the PCM. Therefore, a thorough inspection and/or repair of the wiring harness at the transaxle 20-way connector for one or more of the following conditions may be warranted. ^ The wiring harness is stretched too tightly or other components are pressing on the connector body itself causing a downward pressure on the connector body and possible intermittent contact of the wiring terminals. Ensure proper clearance to any other components and wiring (i.e. hoses, battery cables, etc.). ^ The terminals are not fully seated into the cavity of the connector body. ^ The male terminals in the transaxle portion of the connector may be in the wrong position (i.e. bent). ^ The female terminals may be loose and are not making proper contact. Check the tension with the proper terminal tester from the GM Terminal Test Kit J 35616-A or J 35616-92. If the tension is low, replace the terminal. Do not try to re-form the terminal. ^ The crimp of the terminal to the wire may not be satisfactory (i.e. loose, over insulation, etc.). ^ The wiring connector is not properly seated and locked in position. Ensure proper seating of the connector into the transaxle and that the connector is properly locked in place. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 02-07-30-022B > Oct > 03 > A/T - MIL/SES Lamp ON/Multiple A/T DTC's Set > Page 7665 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 02-07-30-022B > Oct > 03 > A/T - MIL/SES Lamp ON/Multiple A/T DTC's Set Wiring Harness: All Technical Service Bulletins A/T - MIL/SES Lamp ON/Multiple A/T DTC's Set Bulletin No.: 02-07-30-022B Date: October 20, 2003 TECHNICAL Subject: Service Engine Soon (SES) Light On With DTCs P0716 and/or P0717, P0730, P0753, P0758, P1860, P1887, or other Miscellaneous Transmission Trouble Codes Set (Repair Wiring at Transaxle Wiring Pass-thru Connector) Models: 2000-2004 Buick Century, LeSabre, Park Avenue, Regal 2003-2004 Buick Rendezvous 2000-2001 Chevrolet Lumina 2000-2004 Chevrolet Cavalier, Impala, Malibu, Monte Carlo, Venture 2004 Chevrolet Classic 2000-2002 Oldsmobile Intrigue 2000-2003 Oldsmobile Aurora 2000-2004 Oldsmobile Alero, Silhouette 2000-2004 Pontiac Bonneville, Grand Am, Grand Prix, Montana, Sunfire 2001-2004 Pontiac Aztek 2000 Toyota Cavalier with 4T65-E, 4T40-E or 4T45-E Transaxle (RPOs MN3, MN7, M15, M76, MN4, MN5) Supercede: This bulletin is being revised to add the 2004 model year as well as the Chevrolet Classic model. Please discard Corporate Bulletin Number 02-07-30-022A (Section 07-Transmission/Transaxle). Condition Some customers may comment that the Service Engine Soon (SES) indicator is illuminated and that while the light is illuminated, transmission shifts are extremely harsh. Cause These types of conditions may be caused by an intermittent connection at the transaxle 20-way connector to the wiring harness interface. Correction If a DTC was recorded and the Freeze Frame and Failure Records back it up, a problem existed at one time with the wiring and/or the connectors between the transaxle and the PCM. Therefore, a thorough inspection and/or repair of the wiring harness at the transaxle 20-way connector for one or more of the following conditions may be warranted. ^ The wiring harness is stretched too tightly or other components are pressing on the connector body itself causing a downward pressure on the connector body and possible intermittent contact of the wiring terminals. Ensure proper clearance to any other components and wiring (i.e. hoses, battery cables, etc.). ^ The terminals are not fully seated into the cavity of the connector body. ^ The male terminals in the transaxle portion of the connector may be in the wrong position (i.e. bent). ^ The female terminals may be loose and are not making proper contact. Check the tension with the proper terminal tester from the GM Terminal Test Kit J 35616-A or J 35616-92. If the tension is low, replace the terminal. Do not try to re-form the terminal. ^ The crimp of the terminal to the wire may not be satisfactory (i.e. loose, over insulation, etc.). ^ The wiring connector is not properly seated and locked in position. Ensure proper seating of the connector into the transaxle and that the connector is properly locked in place. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 02-07-30-022B > Oct > 03 > A/T - MIL/SES Lamp ON/Multiple A/T DTC's Set > Page 7671 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Page 7672 Wiring Harness: Service and Repair Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Use a small flat-bladed tool in order to remove the wiring harness from the solenoid valve(s) (315A, 315B, 322, 334, and/or 440), TFP manual valve position switch (95) and/or the temperature sensor (391). 3. Remove the wiring harness (224). 4. Remove the clips retaining the solenoid(s). 5. Remove the solenoid(s). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Page 7673 6. Remove the 2-3 shift solenoid (315B). 7. Inspect the wiring harness (224). Installation Procedure 1. Install the 2-3 shift solenoid (315B). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Page 7674 2. Install the solenoid(s). 3. Install the retaining clips. 4. Install the wiring harness (224). 5. Install the wiring harness to the solenoid valve(s) (315A, 315B, 322, 334, and/or 440), TFP manual valve position switch (395) and/or the temperature sensor (391). 6. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > System Information > Technical Service Bulletins > M/T - Hydraulic Clutch Bleeding Procedure Improvement Clutch Hydraulic System: Technical Service Bulletins M/T - Hydraulic Clutch Bleeding Procedure Improvement Bulletin No.: 01-07-31-002B Date: November 01, 2006 INFORMATION Subject: Improved Bleeding Procedure for Hydraulic Clutch Release System Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2007 and Prior Chevrolet and GMC 6-7F T-Series Medium Duty Tilt Cab Models 2007 and Prior Isuzu F-Series Medium Duty Tilt Cab Models 2006-2007 HUMMER H3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 01-07-31-002A (Section 07 - Transmission/Transaxle). This bulletin is being issued to inform dealers of an improved procedure to aid in the ease of bleeding the clutch hydraulic system for the above listed vehicles. This procedure can be used anytime air is introduced into the hydraulic system. Following this procedure may also reduce the number of unnecessary parts replaced for low clutch pedal reserve and high shift effort. Verify that all the lines and fittings are dry and secure. Clean the dirt and grease from the reservoir cap in order to ensure that no foreign substances enter the system. Remove the reservoir cap. Fill the reservoir to the proper level with the required fluid. Attach the J 43485 (Adapter) to the J 35555 (Mity Vac), or equivalent. Brake fluid will deteriorate the rubber on J 43485. Use a clean shop cloth to wipe away the fluid after each use. Place and hold the adapter on the reservoir filler neck to ensure a tight fit. In some cases, the adapter will fit into the reservoir opening. Apply a vacuum of 51-68 kPa (15-20 hg) and remove the adapter. Refill the reservoir to the proper level. Repeat Steps 6 and 7. If needed, refill the reservoir and continue to pull a vacuum until no more bubbles can be seen in the reservoir or until the fluid level no longer drops. The vehicle will move if started in gear before the Actuator Cylinder is refilled and operational. Start the vehicle the first time in neutral to help prevent personal injury from vehicle movement and see if the transmission will shift easily into gear. Pump the clutch pedal until firm (to refill actuator cylinder). Add additional fluid if needed. Test drive vehicle to ensure proper operation. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Technical Service Bulletins > A/T - Shift Lock Control Feature Function Shift Interlock: Technical Service Bulletins A/T - Shift Lock Control Feature Function Bulletin No.: 03-07-30-043A Date: May 25, 2006 INFORMATION Subject: Information Regarding Automatic Transmission Shift Lock Control Function Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 03-07-30-043 (Section 07 - Transmission/Transaxle). This bulletin is being issued to better explain how the Automatic Transmission Shift Lock Control (formerly known as Brake Transmission Shift Interlock (BTSI)) feature is intended to operate. Revised wording regarding the shift lock control system began appearing in the Owner Manuals beginning with the 2004 model year. The shift lock control feature was intended to prevent drivers from shifting out of Park with the vehicle running without the brakes applied. However, if the ignition switch is in the Accessory (ACC) position, it may be possible on some vehicles to move the shift lever out of Park WITHOUT first activating the brake. The shift lock control system is ONLY active when the ignition switch is in the RUN or ON position. This means that when the ignition switch is in the RUN or ON position, the shift lever cannot be moved out of the Park position without activating the brake. Some owners may feel that the shift lock control system prevents an unattended child from moving the vehicle. Please stress to owners, as stated in the Owner Manual, that children should NEVER be left unattended in a vehicle, even if the ignition key has been removed from the vehicle. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Diagrams Axle Shaft Assembly: Diagrams Tripot Design Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Diagrams > Page 7689 Axle Shaft Assembly: Description and Operation Front wheel drive axles are flexible assemblies. Front wheel drive axles consist of the following components: A front wheel drive shaft tripot joint (inner joint) - A front wheel drive shaft constant velocity joint (outer joint) - A front wheel drive shaft The front wheel drive shaft connects the front wheel drive shaft tripot joint and the front wheel drive shaft constant velocity joint. The front wheel drive shaft tripot joint is completely flexible. The front wheel drive shaft tripot joint can move in and out. The front wheel drive shaft constant velocity joint is flexible, but the front wheel drive shaft constant velocity joint cannot move in and out. Boots (Seals) And Clamps The front wheel drive shaft constant velocity joint and the front wheel drive shaft tripot joint boots (seals) in the front wheel drive axle are made of a thermoplastic material. The clamps in front wheel drive axle are made of stainless steel. The boot (seal) provides the following functions: Protection of the internal parts of the front wheel drive shaft constant velocity joint and the front wheel drive shaft tripot joint. The boot (seal) protects the grease from the following sources of damage: Harmful atmospheric conditions (such as extreme temperatures or ozone gas) - Foreign material (such as dirt or water) - Allows angular movement and the axial movement of the front wheel drive shaft tripot joint. - Allows angular movement of the front wheel drive shaft constant velocity joint. Important: Protect the boots (seals) from sharp tools and from the sharp edges of the surrounding components. Any damage to the boots (seals) or the clamps will result in leakage. Leakage will allow water to leak into the front wheel drive shaft tripot joint and the front wheel drive shaft constant velocity joints. Leakage will also allow grease to leak out of the front wheel drive shaft tripot joints and the front wheel drive shaft constant velocity joints. Leakage may cause noisy front wheel drive axle operation and eventual failure of the internal components. The clamps provide a leak proof connection for the front wheel drive shaft tripot joint and the front wheel drive shaft constant velocity joint at the following locations: The housing - The front wheel drive shaft The thermoplastic material performs well under normal conditions and normal operation. However, the material is not strong enough to withstand the following conditions: Abusive handling - Damage from sharp objects (such as sharp tools or any sharp edges of the surrounding components in the vehicle). Front Wheel Drive Shaft Tri-pot Joint (Inner Joint) The front wheel drive shaft tripot joint is made with the tripot design without an over-extension limitation retainer. The joint is constructed as follows for vehicles that are equipped with an automatic transmission: The left front wheel drive axle has a female spline. The female spline installs over a stub shaft that protrudes from the transaxle. - The right front wheel drive axle has a male spline. The right front wheel drive axle uses barrel type snap rings in order to interlock with the transaxle gears. Front Wheel Drive Shaft Constant Velocity Joint (Outer Joint) The front wheel drive shaft constant velocity joint is made with the Rzeppa joint design. The shaft end (which mates with the knuckle/hub) has a helical spline. The helical spline ensures a tight, press-type fit. This design prevents end play between the hub bearing and the front wheel drive axle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Testing and Inspection > Click Noise In Turns Axle Shaft Assembly: Testing and Inspection Click Noise In Turns A worn or damaged front wheel drive shaft constant velocity joint may cause a clicking noise during turns. If a clicking noise occurs, inspect for a cut or damaged front wheel drive shaft constant velocity joint boot. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Testing and Inspection > Click Noise In Turns > Page 7692 Axle Shaft Assembly: Testing and Inspection Clunk When Accelerating From Coast A worn or damaged front wheel drive shaft constant velocity joint or a front wheel drive shaft tri-pot joint can cause a clunk during acceleration from coast to drive. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Testing and Inspection > Click Noise In Turns > Page 7693 Axle Shaft Assembly: Testing and Inspection Shudder or Vibration During Acceleration For information on a shudder or a vibration, refer to Front Wheel Driveline Vibrations in Vibration Diagnosis and Correction. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement Axle Shaft Assembly: Service and Repair Wheel Drive Shaft Inner Joint and Boot Replacement Disassembly Procedure - Tools Required J 8059 Snap Ring Pliers Notice: With removal of the halfshaft for any reason, the transmission sealing surface (the tripot male/female shank of the halfshaft) should be inspected for corrosion. If corrosion is evident, the surface should be cleaned with 320 grit cloth or equivalent. Transmission fluid may be used to clean off any remaining debris. The surface should be wiped dry and the halfshaft reinstalled free of any buildup. 1. Use a hand grinder in order to cut through the swage ring. Do not damage the tripot housing (1). 2. Remove the large boot retaining clamp from the tripot joint with side cutter. 3. Dispose of the large boot retaining clamp. Notice: Do not cut through the halfshaft inboard boot and damage sealing surface of the outer housing and the trilobal tripot bushing. 4. Separate the inboard boot (4) from the trilobal tripot bushing (3) at the large diameter. 5. Slide the boot (4) away from the joint along the halfshaft bar. 6. Remove the housing (1) from the tripot joint spider (2) and the halfshaft bar. 7. Remove the trilobal tripot bushing (3) from the housing (1). 8. Spread the spacer rings (1) and (3) using J 8059 (or equivalent) to remove the spider assembly (2). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7696 9. Remove the following items: - The spacer ring (1) - The spider assembly (2) - The second spacer ring (3) - The inboard boot (4) 10. Clean the halfshaft bar (5). Use a wire brush to remove any rust in the boot mounting area (grooves). 11. Inspect the following items on the spider assembly (2): - The needle roller - The needle bearings - The trunnion 12. Check the tripot housing for unusual wear, cracks, or other damage. 13. Replace any damaged parts. Assembly Procedure - Tools Required J 35910 Earless Clamp Tool - J 41048 Small Swage Tool 1. Place the new swage ring (2) onto the small end of the joint boot (1). Slide the joint boot (1) and the swage ring (2) onto the halfshaft bar. 2. Position the small end of the joint boot (1) into the joint boot groove (3) on the halfshaft bar. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7697 3. Mount J 41048 in a vise and proceed as follows: 3.1. Position the outboard end (1) of the halfshaft assembly in tool J 41048. 3.2. Align the top of boot neck on the bottom die using the indicator. 3.3. Place the top half of the J 41048 on the lower half of the J 41048. 3.4. Before proceeding, ensure there are no pinch points on the boot. This could cause damage to the boot. 3.5. Insert the bolts (2). 3.6. Tighten the bolts by hand until snug. Notice: Refer to Fastener Notice in Service Precautions. 4. Align the following items: - The inboard boot (1) - The swage ring (2) - Tighten each bolt of J 41048 180° at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed. 5. Install the spacer ring (3) and spider assembly (2) onto the halfshaft bar (4) using J 8059. 6. Install the other spacer ring (1) using J 8059 in the groove at the end of the halfshaft bar. Ensure both rings are fully seated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7698 Important: Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1). 7. Place approximately half of the grease from the service kit in the inboard boot. Use the remainder of the grease to repack the housing (1). 8. Install the trilobal tripot bushing (3) to the housing (1). 9. Position the larger new boot retaining clamp (2) on the boot. 10. Slide the housing (1) over the spider assembly on the halfshaft bar. 11. Slide the large diameter of the boot (2), with the larger clamp (3) in place, over the outside of the trilobal tripot bushing and locate the lip of the boot in the groove. Important: The boot must not be dimpled, stretched out or out of shape in any way. If the boot is not shaped correctly, carefully insert a thin flat blunt tool (no sharp edges) between the large boot opening and the trilobal tripot bushing in order to equalize the pressure. Shape the boot properly by hand. Remove the tool. 12. Position the joint assembly at the proper vehicle dimension. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7699 13. Align the following items while latching: - The boot (3) - The tripot housing (2) - The large boot retaining clamp - Crimp the boot retaining clamp with J 35910 to 176 Nm (130 ft. lbs.). Add the breaker bar (5) and the torque wrench (4) to J35910 if necessary. 14. Check the gap dimension on the clamp ear. If gap dimension is larger than shown, continue tightening until gap dimension is reached. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7700 Axle Shaft Assembly: Service and Repair Wheel Drive Shaft Outer Joint and Boot Replacement Disassembly Procedure - Tools Required J 8059 Snap Ring Pliers 1. Remove the large boot retaining clamp from the CV joint with a side cutter. Discard the boot retaining clamp. 2. Remove the small boot retaining clamp from the halfshaft bar with a side cutter. Discard the boot retaining clamp. 3. Separate the outboard boot (5) from CV joint outer race (1) at the large diameter and slide the boot (5) away from the CV joint along the bar (4). 4. Wipe the grease from the face of the CV joint inner race (2). 5. Spread the ears on the race retaining ring (3) using J 8059 and remove the CV joint assembly from the bar (4). 6. Remove the boot (5) from the bar (4). 7. Use a brass drift and a hammer to gently tap on the CV joint cage (1) until it is tilted enough to remove the first chrome alloy ball (2). 8. Tilt cage in the opposite direction to remove the opposing ball (2). 9. Repeat this process until all six balls are removed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7701 10. Position the CV joint cage (4) and the CV joint inner race 90 degrees to the centerline of the CV joint outer race (1) and align the CV joint cage windows (3) with the lands of the CV joint outer race (1). 11. Remove the CV joint cage (4) and the CV joint inner race from the CV joint outer race (1). 12. Rotate the CV joint inner race 90° to the centerline of the CV joint cage with the lands of the CV joint inner race (1) aligned with the windows of the CV joint cage (2). 13. Pivot the inner race into the cage window (2) and remove the inner race (1). 14. Clean the following items thoroughly with cleaning solvent: - The inner and outer race assemblies - The CV joint cage - The balls 15. Remove all traces of old grease and any contaminates. 16. Dry all the parts. Assembly Procedure Tools Required J 35910 Earred Clamp Tool - J 41048 Small Swage Tool 1. Place the new swage ring (2) onto the small end of the joint boot (1). Slide the boot (1) and the swage ring (2) onto the halfshaft bar. 2. Position the small end of the boot (1) into the boot groove (3) on the halfshaft bar. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7702 3. Mount J 41048 in a vise and proceed as follows: 3.1. Position the outboard end (1) of the halfshaft assembly in tool J 41048. 3.2. Align the top of boot neck on the bottom die using the indicator. 3.3. Place the top half of the J 41048 on the lower half of the J 41048. 3.4. Before proceeding, ensure there are no pinch points on the boot. This could cause damage to the boot. 3.5. Insert the bolts (2). 3.6. Tighten the bolts by hand until snug. Notice: Refer to Fastener Notice in Service Precautions. 4. Align the following items: - The boot (1) - The swage ring (2) - Tighten each bolt of J 41048 180° at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed. 5. Put a light c oat of grease from the service kit on the ball grooves of the inner race and the outer race (1). 6. Hold inner race 90 degrees to the centerline of the cage (4) with the lands of the inner race aligned with the windows of the cage and insert the Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7703 inner race into the cage. 7. Hold the cage and the inner race 90° to the centerline of the outer race (1) and align the cage windows (3) with the lands of the outer race (2). Important: Ensure that the retaining ring side of the inner race faces the halfshaft bar. 8. Place the cage (4) and the inner race into the outer race (1). 9. Insert the first chrome ball then tilt the cage in the opposite direction to insert the opposing ball. 10. Repeat this process until all six balls are in place. 11. Place approximately half the grease from the service kit inside the outboard boot and pack the CV joint with the remaining grease. 12. Push the CV joint (2) onto the halfshaft bar (1) until the retaining ring is seated in the groove on the bar. Important: The outboard boot (1) must not be dimpled, stretched or out of shape in any way. If the boot (1) is not shaped correctly, equalize the pressure in the boot (1) and shape the boot (1) properly by hand. 13. Slide large diameter of the outboard boot (1) with the large boot retaining clamp (2) in place over the outside of the CV joint outer race (3) and locate the boot lip in the groove on the CV joint outer race (3). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7704 14. Crimp the boot retaining clamp (1) using J 35910, a breaker bar (3), and a torque wrench (2). - Tighten to 176 Nm (130 ft. lbs.). 15. Check the gap dimension on the clamp ear. If the gap dimension is larger than shown, continue tightening until gap dimension is reached. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7705 Axle Shaft Assembly: Service and Repair Wheel Drive Shafts Replacement Removal Procedure - Tools Required J 2619-01 Slide Hammer - J 28733-B Front Hub Spindle Remover - J 29794 Extension - J 33008 Axle Shaft Remover Caution: To prevent personal injury and/or component damage, do not allow the weight of the vehicle to load the front wheels, or attempt to operate the vehicle, when the wheel drive shaft(s) or wheel drive shaft nut(s) are removed. To do so may cause the inner bearing race to separate, resulting in damage to brake and suspension components and loss of vehicle control. Important: Prevent the seals (boots) from contacting the other components in order to prevent damage to the seals (boots). 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the wheel and the tire. Refer to Tire and Wheel Removal and Installation in Steering and Suspension. 3. Remove the stabilizer shaft link. Refer to Stabilizer Shaft Link Replacement in Steering and Suspension. 4. Remove the front wheel drive shaft nut. Insert a drift or a flat-bladed tool into the caliper and the rotor to prevent the rotor from turning. 5. Disconnect the outer tie rod assembly from the steering knuckle. Refer to Tie Rod End Replacement - Outer in Steering and Suspension. 6. Separate the ball joint from the steering knuckle. Refer to Lower Ball Joint Replacement in Steering and Suspension. Caution: Do not attempt to move vehicle with drive axle(s) removed from wheel bearing. Wheel(s) could fall off, dropping vehicle to the ground and causing personal injury or damage to the vehicle. 7. Separate the front wheel drive axle from the front wheel drive shaft bearing using the J 28733-B. The nut can be partially reinstalled to protect the threads. 8. Remove the front wheel drive axle from the transaxle. - Right Side: Use the J 33003, the J29794 and the J2619-01 to separate the axle from the transaxle. - Left Side: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7706 - Use the frame for leverage. - Place a flat-bladed tool in the groove on the front wheel drive shaft tripot joint (inner joint). - Separate the front wheel drive axle from the transaxle. Installation Procedure Important: Prevent the boots (seals) from contacting the other components in order to prevent damage to the boots (seals). 1. Seat the front wheel drive axle into the transaxle. 2. Verify that the front wheel drive shaft retaining ring is properly seated. Grasp the inner housing and pull the inner housing outboard. Do not pull on the front wheel drive axle shaft. The front wheel drive axle will remain in place when the front wheel drive shaft retaining ring is properly seated. 3. Install the front wheel drive axle into the front wheel drive shaft bearing. 4. Connect the ball joint to the steering knuckle. Refer to Lower Ball Joint Replacement in Steering and Suspension. 5. Connect the outer tie rod assembly to the steering knuckle. Refer to Tie Rod End Replacement Outer in Steering and Suspension. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 6. Install a new front wheel drive shaft nut. Insert a drift or a flat-bladed tool into the caliper and the rotor to prevent the rotor from turning. - Tighten the front wheel drive shaft nut to 215 Nm (159 ft. lbs.). 7. Install the stabilizer shaft link. Refer to Stabilizer Shaft Link Replacement in Steering and Suspension. 8. Install the wheel and the tire. Refer to Tire and Wheel Removal and Installation in Steering and Suspension. 9. Lower the vehicle. 10. Inspect the transaxle fluid level. 11. Inspect the wheel alignment. Refer to Measuring Wheel Alignment in Steering and Suspension. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Page 7707 Axle Shaft Assembly: Tools and Equipment Part 1 of 2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Page 7708 Part 2 of 2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use GC Wheel Bearing Grease. GC ....................................................................................................................................................... ............. Wheel Bearing Grease, NLGI Classification Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement Wheel Bearing: Service and Repair Front Wheel Drive Shaft Bearing Replacement Front Wheel Drive Shaft Bearing Replacement Removal Procedure Tools Required ^ J 28733-B Spindle Remover 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Disconnect the wheel speed sensor electrical connector (2). 4. Remove the wheel speed sensor electrical connector from the bracket. 5. Remove the brake caliper bracket with the brake caliper. Refer to Brake Caliper Bracket Replacement (Front) or Brake Caliper Bracket Replacement (Rear) in Brakes and Traction Control. 6. Remove the brake rotor. Refer to Brake Rotor Replacement (Front) or Brake Rotor Replacement (Rear) in Brakes and Traction Control. 7. Remove the wheel drive shaft nut. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement > Page 7714 8. Use three wheel nuts in order to attach the J 28733-B to the wheel bearing/hub. 9. Use the J 28733-B in order to push the wheel drive shaft out of the wheel bearing/hub. 10. Remove and DISCARD the wheel bearing/hub bolts. Important: Ensure that the wheel drive shaft outer seal (boot) is not damaged. 11. Remove the wheel bearing/hub. Installation Procedure 1. Install the wheel bearing/hub. Caution: These fasteners MUST be replaced with new fasteners anytime they become loose or are removed. Failure to replace these fasteners after they become loose or are removed may cause loss of vehicle control and personal injury. Notice: Refer to Fastener Notice in Service Precautions Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement > Page 7715 2. Install NEW wheel bearing/hub bolts. Tighten the NEW wheel bearing/hub bolts to 130 Nm (96 ft. lbs.). 3. Install the wheel drive shaft nut. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts. 4. Install the brake rotor. Refer to Brake Rotor Replacement (Front) or Brake Rotor Replacement (Rear) in Brakes and Traction Control. 5. Install the brake caliper bracket with the brake caliper. Refer to Brake Caliper Bracket Replacement (Front) or Brake Caliper Bracket Replacement (Rear) in Brakes and Traction Control. Important: Ensure that the connector clip engages the bracket properly. 6. Install the wheel speed sensor electrical connector to the bracket. 7. Connect the wheel speed sensor electrical connector (2). 8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 9. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement > Page 7716 Wheel Bearing: Service and Repair Wheel Bearing/Hub Replacement-Rear Wheel Bearing/Hub Replacement - Rear Removal Procedure The wheel bearing in the rear wheel hub is integrated into one unit. The hub is non-serviceable. If the hub and/or bearing is damaged, replace the complete hub and bearing assembly. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tires and wheels. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Remove the rear caliper and bracket. Refer to Brake Caliper Bracket Replacement (Rear) in Disc Brakes. 4. Remove the brake rotor. Refer to Brake Rotor Replacement (Rear) in Disc Brakes. 5. Disconnect the ABS electrical connector from the wheel speed sensor (1). Refer to Wheel Speed Sensor Replacement (Rear) in Antilock Brakes. 6. Remove the rear wheel hub-to-knuckle bolts. 7. Remove the rear wheel hub and park brake assembly from the knuckle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement > Page 7717 8. Remove the parking brake lever bracket (8). 9. Remove the parking brake actuator (6). Installation Procedure 1. Install the parking brake lever bracket (8). 2. Install the parking brake actuator (6). 3. Install the rear wheel hub and park brake assembly to the knuckle. Notice: Refer to Fastener Notice in Service Precautions. 4. Install new rear wheel hub-to-knuckle bolts. Tighten the hub mounting bolts to 75 Nm (55 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement > Page 7718 5. Connect the ABS electrical connector to the wheel speed sensor (1). Refer to Wheel Speed Sensor Replacement (Rear) in Antilock Brakes. 6. Install the brake rotor. Refer to Brake Rotor Replacement (Rear) in Disc Brakes. 7. Install the rear caliper and bracket. Refer to Brake Caliper Bracket Replacement (Rear) in Disc Brakes. 8. Install the tires and wheels. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 9. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Wheel Drive Shaft Nut 159 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Flywheel Bolts 52 lb. ft. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 7726 Flex Plate: Service and Repair Removal Procedure 1. Remove the automatic transaxle. Refer to Transmission Replacement in Transmission and Drivetrain. 2. Secure the flywheel in order to prevent rotation. 3. Loosen the six engine flywheel bolts. 4. Remove five of the six flywheel bolts leaving one bolt at the top of the crankshaft rotation. 5. Grip the flywheel and remove the remaining bolt. Do not drop the flywheel when removing the final bolt. 6. Remove the engine flywheel and the flywheel retainer. 7. Clean the engine flywheel bolt threads and bolt holes. 8. If you are not replacing the flywheel, clean and inspect the engine flywheel. Refer to Engine Flywheel Clean and Inspect. Installation Procedure 1. Install the flywheel retainer and the flywheel. Refer to Engine Flywheel Installation. 2. Install the automatic transaxle. Refer to Transmission Replacement in Transmission and Drivetrain. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Component Information > Technical Service Bulletins > Manual Transmission - M/T Operating Characteristics Manual Transmission/Transaxle: Technical Service Bulletins Manual Transmission - M/T Operating Characteristics INFORMATION Bulletin No.: 03-07-29-004G Date: December 15, 2010 Subject: Manual Transmission Operating Characteristics Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2009 and Prior Chevrolet and GMC Medium Duty Trucks 2006-2010 HUMMER H3 with Manual Transmission Supercede: This bulletin is being revised to add the 2011 model year and to add Cold Operation information. Please discard Corporate Bulletin Number 03-07-29-004F (Section 07 Transmission/Transaxle). Important Even though this bulletin attempts to cover operating characteristics of manual transmissions, it cannot be all inclusive. Be sure to compare any questionable concerns to a similar vehicle and if possible, with similar mileage. Even though many of the conditions are described as characteristics and may not be durability issues, GM may attempt to improve specific issues for customer satisfaction. The purpose of this bulletin is to assist in identifying characteristics of manual transmissions that repair attempts will not change. The following are explanations and examples of conditions that will generally occur in all manual transmissions. All noises will vary between transmissions due to build variation, type of transmission (usually the more heavy duty, the more noise), type of flywheel and clutch, level of insulation, etc. Basic Information Many transmission noises are created by the firing pulses of the engine. Each firing pulse creates a sudden change in angular acceleration at the crankshaft. These changes in speed can be reduced with clutch damper springs and dual mass flywheels. However, some speed variation will make it through to the transmission. This can create noise as the various gears will accel and decel against each other because of required clearances. Cold Operation Manual transmission operation will be affected by temperature because the transmission fluid will be thicker when cold. The thicker fluid will increase the amount of force needed to shift the transmission when cold. The likelihood of gear clash will also increase due to the greater time needed for the synchronizer assembly to perform its function. Therefore when the transmission is cold, or before it has reached operating temperature, quick, hard shifts should be avoided to prevent damage to the transmission. Gear Rattle Rattling or grinding (not to be confused with a missed shift type of grinding, also described as a combustion knock type of noise) type noises usually occur while operating the engine at low RPMs (lugging the engine). This can occur while accelerating from a stop (for example, a Corvette) or while operating at low RPMs while under a load (for example, Kodiak in a lower gear and at low engine speed). Vehicles equipped with a dual-mass flywheel (for example, a 3500 HD Sierra with the 6-speed manual and Duramax(R)) will have reduced noise levels as compared to vehicles without (for example, a 4500 Kodiak with the 6-speed manual and Duramax(R)). However, dual-mass flywheels do not eliminate all noise. Neutral Rattle There are often concerns of rattle while idling in neutral with the clutch engaged. This is related to the changes in angular acceleration described earlier. This is a light rattle, and once again, vehicles with dual mass flywheels will have reduced noise. If the engine is shut off while idling in neutral with the clutch engaged, the sudden stop of the engine will create a rapid change in angular acceleration that even dual mass flywheels cannot compensate. Because of the mass of all the components, this will create a noise. This type of noise should not be heard if the clutch is released (pedal pushed to the floor). Backlash Backlash noise is created when changing engine or driveline loading. This can occur when accelerating from a stop, coming to a stop, or applying and releasing the throttle (loading and unloading the driveline). This will vary based on vehicle type, build variations, driver input, vehicle loading, etc. and is created from the necessary clearance between all of the mating gears in the transmission, axle(s) and transfer case (if equipped). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Component Information > Technical Service Bulletins > Manual Transmission - M/T Operating Characteristics > Page 7731 Shift Effort Shift effort will vary among different style transmissions and synchronizer designs. Usually the more heavy duty the transmission, the higher the shift effort because of the increased mass of the components. Shift effort can also be higher in cold weather because the fluid will be thicker. Medium duty transmissions will not shift as quickly as a Corvette transmission. To reduce shift effort, do not attempt to rush the shift - allow the synchronizers to work as designed. Shifting harder will only increase the chance of rushing past the synchronizer leading to grinding while shifting. Non-Synchronized Gears Some light duty truck transmissions in 1st gear (creeper-gear) and reverse gears in various transmissions, along with all gears in some medium duty transmissions, may be non-synchronized. This means there is not a mechanism to match input and output shaft speeds to allow for a smooth shift. This function is left up to the driver. This can be noticed if a shift into 1st or reverse is attempted while the vehicle is rolling or before the input shaft stops rotating leading to a gear grind. The grinding can be reduced by coming to a complete stop and pausing for a moment before shifting into the 1st or reverse gear. Some slight grinding can be expected. In medium duty non-synchronized transmissions, the driver must match input shaft (engine) speed to output shaft (driveshaft) speed with every shift. This can be accomplished by double clutching, or by using other methods. If the driver is not able to perform this function properly, there will be gear grinding with each improperly completed shift. Driver training may be required to correct this condition. Clutch brakes are used in medium duty non-synchronized transmissions to allow a shift into gear at a stop. The clutch brake is used to stop the input shaft from spinning, allowing a shift into gear at a stop without grinding. The clutch brake is activated by pressing the clutch pedal all the way to the floor. When the clutch brake is used, it is possible to have a blocked shift with the vehicle stationary. If this occurs, engage the clutch slightly to rotate the input gear to allow the shift. The clutch brake is intended to only be used while at a stop. Care must be taken to not activate the clutch brake while shifting between gears. This could lead to excessive grinding or a blocked or missed shift. Skip Shift Currently, the Cadillac CTS-V, Pontiac GTO, Chevrolet Corvette and Camaro SS (other models may follow) equipped with the 6-speed manual transmission have a feature referred to as a "skip-shift." This feature only allows a shift from 1st to 4th gear when the indicator lamp is illuminated on the dash. Dealers cannot disable this feature as it was established to help meet fuel economy standards. The conditions for this feature are: engine coolant at normal operating temperature, vehicle speed of 24-31 km/h (15-19 mph), 21% or less throttle being used (refer to Service Information or the Owner Manual for more details.) Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Fluid Pressure Sensor/Switch: Specifications TFP Switch to Case 120 ft.lb TFP Switch to Case Cover 106 in.lb TFP Switch to Valve Body 70 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 7737 Fluid Pressure Sensor/Switch: Locations Internal Electronic Component Locations Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Fluid Pressure Man Vlv Position Switch Connector, Harness Side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Fluid Pressure Man Vlv Position Switch Connector, Harness Side > Page 7740 Fluid Pressure Sensor/Switch: Diagrams 4T65-E Automatic Transaxle Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Fluid Pressure Manual Valve Position Switch Replacement Fluid Pressure Sensor/Switch: Service and Repair Fluid Pressure Manual Valve Position Switch Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the control valve body bolts (375, 379 and 381) that mount the fluid pressure manual valve position switch to the control valve body (300). 4. Carefully remove the fluid pressure manual valve position switch (395). Handle the switch carefully, the fluid pressure manual valve position switch is very delicate. 5. Inspect the fluid pressure manual valve position switch (395) for the following conditions: - Damaged electrical connector terminals - Damaged seals - Damaged switch membranes - Debris on the switch membranes Installation Procedure 1. Carefully install the fluid pressure manual valve position switch (395). Handle the switch carefully, the fluid pressure manual valve position switch is very delicate. Notice: Refer to Fastener Notice in Service Precautions 2. Install the control valve body bolts (375, 379, and 381) that mount the fluid pressure manual valve position switch to the control valve body (300). - Tighten the control valve body bolt (375) to 12 Nm (106 inch lbs.). - Tighten the control valve body bolt (379) to 16 Nm (106 inch lbs.). - Tighten the control valve body bolt (381) to 8 Nm (70 inch lbs.). 3. Connect the transaxle wiring harness. 4. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Fluid Pressure Manual Valve Position Switch Replacement > Page 7743 Fluid Pressure Sensor/Switch: Service and Repair Pressure Control Solenoid Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the pressure control solenoid (322). Installation Procedure 1. Install the pressure control solenoid (322). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Inside the automatic transaxle Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 7747 Park Neutral Position (PNP) Switch C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 7751 Transmission Speed Sensor: Service and Repair Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the input speed sensor clip (441) from the case cover. 4. Remove the input speed sensor (440) from the case cover. 5. Inspect the input speed sensor (440) for the following conditions: - Damaged or missing magnet - Damaged housing - Bent or missing electrical terminals - Damaged speed sensor clip (441) Installation Procedure 1. Install the input speed sensor (440) into the case cover. 2. Install the input speed sensor clip (441) into the case cover. 3. Connect the transaxle wiring harness. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 7752 4. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Automatic Transaxle Fluid Temperature (TFT) Sensor Transmission Temperature Sensor/Switch: Locations Automatic Transaxle Fluid Temperature (TFT) Sensor Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Automatic Transaxle Fluid Temperature (TFT) Sensor > Page 7757 Transmission Temperature Sensor/Switch: Locations Transaxle Fluid Temperature (TFT) Sensor Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 7758 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 7759 Transmission Temperature Sensor/Switch: Service and Repair Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement 2. Disconnect the wiring harness assembly from the fluid temperature sensor (391). 3. Remove the fluid temperature sensor (391). Installation Procedure 1. Install the fluid temperature sensor (391). 2. Connect the wiring harness assembly to the with fluid temperature sensor (391). 3. Install the case side cover. Refer to Case Side Cover Replacement Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set Pressure Regulating Solenoid: Customer Interest A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set File In Section: 07 - Transmission/Transaxle Bulletin No.: 0O-07-30-002B Date: July, 2002 TECHNICAL Subject: Slips, Harsh Upshift or Garage Shifts, Launch Shudders, Flares, Erratic Shifts and Intermittent Concerns, DTC P1811 or P0748 Set (Replace Pressure Control Solenoid Valve Assembly) Models: 1997-1999 Buick Riviera 1997-2002 Buick Park Avenue 1998-2002 Buick LeSabre 1999-2002 Buick Regal 2000-2002 Buick Century 2002 Buick Rendezvous 1997-2001 Chevrolet Lumina 1997-2002 Chevrolet Monte Carlo 1999-2002 Chevrolet Venture 2000-2002 Chevrolet Impala 1997-1999 Oldsmobile Eighty Eight 1997-2002 Oldsmobile Silhouette 1998-2002 Oldsmobile Intrigue 2001-2002 Oldsmobile Aurora (3.5L) 1997-2002 Pontiac Bonneville, Grand Prix 1999-2002 Pontiac Transport/Montana 2001-2002 Pontiac Aztek with Hydra-Matic 4T65-E (RPOs MN3, MN7, M15, M76) This bulletin is being revised to add additional models and model years. Please discard Corporate Bulletin Number 00-07-30-002A (Section 07 - Transmission/Transaxle). Condition Some owners of the above vehicles with a HydraMatic 4T65-E transaxle may comment on harsh upshifts or harsh garage shifts, soft shifts, shudders on hard acceleration, or shifts erratic. These conditions may appear intermittently or set a DTC P1811 or P0748. During diagnosis, a low or high line pressure (actual versus desired) may be observed. Cause The above condition may be due to any one of the following which may affect line pressure output: ^ Sediment inside the pressure control (PC) solenoid valve, causing the PC solenoid valve to mechanically bind. ^ Sediment in the valve body, causing the torque signal regulator valve to stick. ^ Incorrect transaxle oil level. Correction Important: Any of the above conditions may be intermittent, therefore, this test should be performed at least three times. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7771 Refer to the Line Pressure Check Procedure in SI, along with the Line Pressure Specification Table shown, to determine if actual versus desired pressures are within the values specified. The Scan Tool is only able to control the PC solenoid valve in PARK and NEUTRAL with the vehicle stopped. This protects the clutches from extremely high or low pressures in DRIVE or REVERSE ranges. Refer to the Line Pressure Specification Table. The pressures in the table assume a temperature of 70°C. The pressure will vary with a change in temperature. If the actual versus desired pressures are not within the values specified, clean the valve body and replace the PC solenoid valve, if necessary. Check the PC solenoid valve actual versus desired pressures to verify the new PC solenoid valve is responding correctly. Refer to the Automatic Transaxle Section of the Service Manual for the proper repair procedure. Line Pressure Check Procedure Tools Required J 21867 Universal Pressure Gauge Set Important: Before performing a line pressure check, verify that the pressure control (PC) solenoid valve is receiving the correct electrical signal from the PCM. 1. Install a Scan Tool. Caution: Keep the brakes applied at all times in order to prevent unexpected vehicle motion. Personal injury may result it the vehicle moves unexpectedly. 2. Start the engine and set the parking brake. 3. Check for a stored Diagnostic Trouble Code (DTC). 4. Repair the vehicle, if necessary. 5. Check the fluid level. Refer to the Transmission Fluid Checking Procedure. 6. Check the manual linkage for proper adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7772 7. Turn the engine OFF. Remove the oil pressure test hole plug and install the J 21867. 8. Put the gear selector in PARK range and set the parking brake. 9. Start the engine and allow the engine to warm up at idle. Notice: Total test running time should not be longer than two minutes, or else transmission damage could occur. 10. Access the PC solenoid valve control test on the Scan Tool. 11. Increase the PC solenoid as shown actual current from 0.0 to 1.0 amps in 0.1 amp increments. Allow the pressure to stabilize for five seconds after each pressure change. Read the corresponding line pressure on the J 21867. 12. Refer to the Line Pressure specification table. Compare the data to the table. 13. If pressure readings differ greatly from the table, refer to Incorrect Line Pressure. 14. Remove the J 21867. 15. Apply sealant, P/N 12345382 (in Canada, P/N 10953489), to the oil pressure test hole plug. Notice: Refer to Fastener Notice in Cautions and Notices. 16. Install the oil pressure test hole plug. Tighten Tighten the oil pressure test hole plug to 12 N.m (106 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7773 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Pressure Control Solenoid Replacement File In Section: 07 - Transmission/Transaxle Bulletin No.: 02-07-30-048 Date: November, 2002 INFORMATION Subject: Pressure Control Solenoid Replacement for 4T65-E, 4T40-E, and 4T45-E Transaxle/Transmission Models: 2000-2003 Buick Century, LeSabre, Park Avenue, Regal 2002-2003 Buick Rendezvous 2000-2001 Chevrolet Lumina 2000-2003 Chevrolet Cavalier, Impala, Malibu, Monte Carlo, Venture 2000-2002 Oldsmobile Intrigue 2000-2003 Oldsmobile Alero, Silhouette 2000-2003 Pontiac Bonneville, Grand Am, Grand Prix, Montana, Sunfire 2001-2003 Pontiac Aztek with RPO Codes MN4, MN5, M13, M15, MN3, MN7 or M76 The pressure control solenoid in the above transaxles has changed for the 2003 models. Important: While the physical dimensions will allow usage of the new solenoid in past model transaxles or usage of the old solenoid in 2003 model transaxles, they should not be interchanged. Interchanging of the pressure control solenoids will result in improper shift characteristics, customer dissatisfaction, and needed repeat repairs. When replacing a pressure control solenoid, be sure to use the correct part number. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement > Page 7779 Parts are currently available from GMSPO. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set Pressure Regulating Solenoid: All Technical Service Bulletins A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set File In Section: 07 - Transmission/Transaxle Bulletin No.: 0O-07-30-002B Date: July, 2002 TECHNICAL Subject: Slips, Harsh Upshift or Garage Shifts, Launch Shudders, Flares, Erratic Shifts and Intermittent Concerns, DTC P1811 or P0748 Set (Replace Pressure Control Solenoid Valve Assembly) Models: 1997-1999 Buick Riviera 1997-2002 Buick Park Avenue 1998-2002 Buick LeSabre 1999-2002 Buick Regal 2000-2002 Buick Century 2002 Buick Rendezvous 1997-2001 Chevrolet Lumina 1997-2002 Chevrolet Monte Carlo 1999-2002 Chevrolet Venture 2000-2002 Chevrolet Impala 1997-1999 Oldsmobile Eighty Eight 1997-2002 Oldsmobile Silhouette 1998-2002 Oldsmobile Intrigue 2001-2002 Oldsmobile Aurora (3.5L) 1997-2002 Pontiac Bonneville, Grand Prix 1999-2002 Pontiac Transport/Montana 2001-2002 Pontiac Aztek with Hydra-Matic 4T65-E (RPOs MN3, MN7, M15, M76) This bulletin is being revised to add additional models and model years. Please discard Corporate Bulletin Number 00-07-30-002A (Section 07 - Transmission/Transaxle). Condition Some owners of the above vehicles with a HydraMatic 4T65-E transaxle may comment on harsh upshifts or harsh garage shifts, soft shifts, shudders on hard acceleration, or shifts erratic. These conditions may appear intermittently or set a DTC P1811 or P0748. During diagnosis, a low or high line pressure (actual versus desired) may be observed. Cause The above condition may be due to any one of the following which may affect line pressure output: ^ Sediment inside the pressure control (PC) solenoid valve, causing the PC solenoid valve to mechanically bind. ^ Sediment in the valve body, causing the torque signal regulator valve to stick. ^ Incorrect transaxle oil level. Correction Important: Any of the above conditions may be intermittent, therefore, this test should be performed at least three times. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7784 Refer to the Line Pressure Check Procedure in SI, along with the Line Pressure Specification Table shown, to determine if actual versus desired pressures are within the values specified. The Scan Tool is only able to control the PC solenoid valve in PARK and NEUTRAL with the vehicle stopped. This protects the clutches from extremely high or low pressures in DRIVE or REVERSE ranges. Refer to the Line Pressure Specification Table. The pressures in the table assume a temperature of 70°C. The pressure will vary with a change in temperature. If the actual versus desired pressures are not within the values specified, clean the valve body and replace the PC solenoid valve, if necessary. Check the PC solenoid valve actual versus desired pressures to verify the new PC solenoid valve is responding correctly. Refer to the Automatic Transaxle Section of the Service Manual for the proper repair procedure. Line Pressure Check Procedure Tools Required J 21867 Universal Pressure Gauge Set Important: Before performing a line pressure check, verify that the pressure control (PC) solenoid valve is receiving the correct electrical signal from the PCM. 1. Install a Scan Tool. Caution: Keep the brakes applied at all times in order to prevent unexpected vehicle motion. Personal injury may result it the vehicle moves unexpectedly. 2. Start the engine and set the parking brake. 3. Check for a stored Diagnostic Trouble Code (DTC). 4. Repair the vehicle, if necessary. 5. Check the fluid level. Refer to the Transmission Fluid Checking Procedure. 6. Check the manual linkage for proper adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7785 7. Turn the engine OFF. Remove the oil pressure test hole plug and install the J 21867. 8. Put the gear selector in PARK range and set the parking brake. 9. Start the engine and allow the engine to warm up at idle. Notice: Total test running time should not be longer than two minutes, or else transmission damage could occur. 10. Access the PC solenoid valve control test on the Scan Tool. 11. Increase the PC solenoid as shown actual current from 0.0 to 1.0 amps in 0.1 amp increments. Allow the pressure to stabilize for five seconds after each pressure change. Read the corresponding line pressure on the J 21867. 12. Refer to the Line Pressure specification table. Compare the data to the table. 13. If pressure readings differ greatly from the table, refer to Incorrect Line Pressure. 14. Remove the J 21867. 15. Apply sealant, P/N 12345382 (in Canada, P/N 10953489), to the oil pressure test hole plug. Notice: Refer to Fastener Notice in Cautions and Notices. 16. Install the oil pressure test hole plug. Tighten Tighten the oil pressure test hole plug to 12 N.m (106 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 00-07-30-002B > Jul > 02 > A/T - 4T65E Harsh Shifts/Shudders/Slips/DTC's Set > Page 7786 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Pressure Control Solenoid Replacement File In Section: 07 - Transmission/Transaxle Bulletin No.: 02-07-30-048 Date: November, 2002 INFORMATION Subject: Pressure Control Solenoid Replacement for 4T65-E, 4T40-E, and 4T45-E Transaxle/Transmission Models: 2000-2003 Buick Century, LeSabre, Park Avenue, Regal 2002-2003 Buick Rendezvous 2000-2001 Chevrolet Lumina 2000-2003 Chevrolet Cavalier, Impala, Malibu, Monte Carlo, Venture 2000-2002 Oldsmobile Intrigue 2000-2003 Oldsmobile Alero, Silhouette 2000-2003 Pontiac Bonneville, Grand Am, Grand Prix, Montana, Sunfire 2001-2003 Pontiac Aztek with RPO Codes MN4, MN5, M13, M15, MN3, MN7 or M76 The pressure control solenoid in the above transaxles has changed for the 2003 models. Important: While the physical dimensions will allow usage of the new solenoid in past model transaxles or usage of the old solenoid in 2003 model transaxles, they should not be interchanged. Interchanging of the pressure control solenoids will result in improper shift characteristics, customer dissatisfaction, and needed repeat repairs. When replacing a pressure control solenoid, be sure to use the correct part number. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 02-07-30-048 > Nov > 02 > A/T - Pressure Control Solenoid Replacement > Page 7792 Parts are currently available from GMSPO. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7793 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7794 Pressure Regulating Solenoid: Description and Operation Pressure Control Solenoid Valve The pressure control (PC) solenoid valve is a precision electronic pressure regulator that controls transmission line pressure based on current flow through its coil windings. As current flow is increased, the magnetic field which is produced by the coil moves the solenoid's plunger further away from the exhaust port. Opening the exhaust port decreases the output fluid pressure, which is regulated by the PC solenoid valve. This ultimately decreases line pressure. The PCM controls the PC solenoid valve based upon various inputs including throttle position, fluid temperature, MAP sensor, and gear state. The PCM controls the PC solenoid valve on a positive duty cycle at a fixed frequency of 292.5 Hz (cycles per second). Duty cycle is defined as the percentage of time when current flows through the solenoid coil during each cycle. A higher duty cycle provides a greater current flow through the solenoid. The high (positive) side of the PC solenoid valve electrical circuit at the PCM controls the PC solenoid valve operation. The PCM provides a ground path for the circuit, monitors average current, and continuously varies the PC solenoid valve duty cycle in order to maintain the correct average current flowing through the PC solenoid valve. The PC solenoid valve resistance should measure between 3-5 ohms when measured at 20°C (68°F). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7795 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid Valve Replacement Removal 1. Remove the case side cover. Refer to Control Valve Body Cover Replacement . 2. Disconnect the transaxle wiring harness. 3. Remove the pressure control solenoid (322). Installation 1. Install the pressure control solenoid (322). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 4. Reset the TAP values. Refer to Adapt Function. Adapt Function The 4T65-E transmission uses a line pressure control system, that has the ability to adapt line pressure to compensate for normal wear of the following parts: - The clutch fiber plates - The springs and seals - The apply bands Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7796 The PCM maintains information for the following transmission adaptive systems: Upshift Adapts (1-2, 2-3 and 3-4) The PCM monitors the automatic transmission input shaft speed (AT ISS) sensor and the vehicle speed sensor (VSS) in order to determine when an upshift has started and completed. The PCM measures the time for the upshift. If the upshift time is longer than a calibrated value, then the PCM will adjust the current to the pressure control (PC) solenoid valve to increase the line pressure for the next shift in the same torque range. If the upshift time is shorter than the calibrated value, then the PCM will decrease the line pressure for the next shift in the same torque range. Steady State Adapts The PCM monitors the AT ISS sensor and the VSS after an upshift in order to determine the amount of clutch slippage. If excessive slippage is detected, then the PCM will adjust the current to the PC solenoid valve in order to increase the line pressure to maintain the proper gear ratio for the commanded gear. The TAP information is divided into 13 units, called cells. The cells are numbered 4 through 16. Each cell represents a given torque range. TAP cell 4 is the lowest adaptable torque range and TAP cell 16 is the highest adaptable torque range. It is normal for TAP cell values to display zero or negative numbers. This indicates that the PCM has adjusted line pressure at or below the calibrated base pressure. Clearing Transmission Adaptive Pressure (TAP) Updating TAP information is a learning function of the PCM designed to maintain acceptable shift times. It is not recommended that TAP information be reset unless one of the following repairs has been made: - Transmission overhaul or replacement - Repair or replacement of an apply or release component (clutch, band, piston, servo) - Repair or replacement of a component or assembly which directly affects line pressure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 2. Remove the center console. Refer to Console Replacement - Front Floor (Impala) or Console Replacement - Front Floor (Monte Carlo) in Instrument Panel, Gauges and Warning Indicators. 3. Disconnect electrical connector from the A/T shift lock control (2). 4. Remove both ends of the Automatic Transmission Shift Lock Control from pivot points (1). Installation Procedure 1. Install the A/T shift lock control upper clip onto upper pivot point, and lower clip onto the lower pivot point. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 7800 2. Install the center console. Refer to Console Replacement - Front Floor (Impala) or Console Replacement - Front Floor (Monte Carlo) in Instrument Panel, Gauges and Warning Indicators. 3. Install the electrical connector to the A/T shift lock control. 4. Connect negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 1-2 Shift Solenoid (1-2 SS) Valve Shift Solenoid: Locations 1-2 Shift Solenoid (1-2 SS) Valve Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 1-2 Shift Solenoid (1-2 SS) Valve > Page 7805 Shift Solenoid: Locations 2-3 Shift Solenoid (2-3 SS) Valve Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2, 3-4 Shift Solenoid Valve Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2, 3-4 Shift Solenoid Valve Connector, Wiring Harness Side > Page 7808 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the 1-2 shift solenoid (315A). Installation Procedure 1. Install the 1-2 shift solenoid (315A). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 7811 Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the 2-3 shift solenoid (315B). Installation Procedure 1. Install the 2-3 shift solenoid (315B). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 7812 Shift Solenoid: Service and Repair Solenoids and Wiring Harness Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Use a small flat-bladed tool in order to remove the wiring harness from the solenoid valve(s) (315A, 315B, 322, 334, and/or 440), TFP manual valve position switch (95) and/or the temperature sensor (391). 3. Remove the wiring harness (224). 4. Remove the clips retaining the solenoid(s). 5. Remove the solenoid(s). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 7813 6. Remove the 2-3 shift solenoid (315B). 7. Inspect the wiring harness (224). Installation Procedure 1. Install the 2-3 shift solenoid (315B). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 7814 2. Install the solenoid(s). 3. Install the retaining clips. 4. Install the wiring harness (224). 5. Install the wiring harness to the solenoid valve(s) (315A, 315B, 322, 334, and/or 440), TFP manual valve position switch (395) and/or the temperature sensor (391). 6. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 7818 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 7819 Torque Converter Clutch Solenoid: Service and Repair Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the torque converter clutch PWM solenoid (334). Installation Procedure 1. Install the torque converter clutch PWM solenoid (334). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Fluid Pressure Sensor/Switch: Specifications TFP Switch to Case 120 ft.lb TFP Switch to Case Cover 106 in.lb TFP Switch to Valve Body 70 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 7825 Fluid Pressure Sensor/Switch: Locations Internal Electronic Component Locations Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Fluid Pressure Man Vlv Position Switch Connector, Harness Side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Fluid Pressure Man Vlv Position Switch Connector, Harness Side > Page 7828 Fluid Pressure Sensor/Switch: Diagrams 4T65-E Automatic Transaxle Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Fluid Pressure Manual Valve Position Switch Replacement Fluid Pressure Sensor/Switch: Service and Repair Fluid Pressure Manual Valve Position Switch Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the control valve body bolts (375, 379 and 381) that mount the fluid pressure manual valve position switch to the control valve body (300). 4. Carefully remove the fluid pressure manual valve position switch (395). Handle the switch carefully, the fluid pressure manual valve position switch is very delicate. 5. Inspect the fluid pressure manual valve position switch (395) for the following conditions: - Damaged electrical connector terminals - Damaged seals - Damaged switch membranes - Debris on the switch membranes Installation Procedure 1. Carefully install the fluid pressure manual valve position switch (395). Handle the switch carefully, the fluid pressure manual valve position switch is very delicate. Notice: Refer to Fastener Notice in Service Precautions 2. Install the control valve body bolts (375, 379, and 381) that mount the fluid pressure manual valve position switch to the control valve body (300). - Tighten the control valve body bolt (375) to 12 Nm (106 inch lbs.). - Tighten the control valve body bolt (379) to 16 Nm (106 inch lbs.). - Tighten the control valve body bolt (381) to 8 Nm (70 inch lbs.). 3. Connect the transaxle wiring harness. 4. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Fluid Pressure Manual Valve Position Switch Replacement > Page 7831 Fluid Pressure Sensor/Switch: Service and Repair Pressure Control Solenoid Replacement Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the pressure control solenoid (322). Installation Procedure 1. Install the pressure control solenoid (322). 2. Connect the transaxle wiring harness. 3. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Inside the automatic transaxle Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 7835 Park Neutral Position (PNP) Switch C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 7839 Transmission Speed Sensor: Service and Repair Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement. 2. Disconnect the transaxle wiring harness. 3. Remove the input speed sensor clip (441) from the case cover. 4. Remove the input speed sensor (440) from the case cover. 5. Inspect the input speed sensor (440) for the following conditions: - Damaged or missing magnet - Damaged housing - Bent or missing electrical terminals - Damaged speed sensor clip (441) Installation Procedure 1. Install the input speed sensor (440) into the case cover. 2. Install the input speed sensor clip (441) into the case cover. 3. Connect the transaxle wiring harness. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 7840 4. Install the case side cover. Refer to Case Side Cover Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Automatic Transaxle Fluid Temperature (TFT) Sensor Transmission Temperature Sensor/Switch: Locations Automatic Transaxle Fluid Temperature (TFT) Sensor Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Automatic Transaxle Fluid Temperature (TFT) Sensor > Page 7845 Transmission Temperature Sensor/Switch: Locations Transaxle Fluid Temperature (TFT) Sensor Inside the automatic transaxle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 7846 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 7847 Transmission Temperature Sensor/Switch: Service and Repair Removal Procedure 1. Remove the case side cover. Refer to Case Side Cover Replacement 2. Disconnect the wiring harness assembly from the fluid temperature sensor (391). 3. Remove the fluid temperature sensor (391). Installation Procedure 1. Install the fluid temperature sensor (391). 2. Connect the wiring harness assembly to the with fluid temperature sensor (391). 3. Install the case side cover. Refer to Case Side Cover Replacement Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Testing and Inspection ABS Light: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Antilock Brakes / Traction Control Systems Testing and Inspection. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON Electronic Brake Control Module: Customer Interest Tire Inflation Monitor - False Message/Lamp ON File In Section: 03 - Suspension Bulletin No.: 01-03-10-008A Date: February, 2002 TECHNICAL Subject: False Tire Inflation Monitor System (TIM) Message/Lamp Illumination (Install New Electronic Brake Traction Control Module - EBTCM) Models: 1999-2001 Buick Century, Regal This bulletin is being revised to add additional Existing ECU Part Numbers. Please discard Corporate Bulletin Number 01-03-1-008 (Section 03-Suspension) Condition Some owners may comment on the "Low Tire Pressure" message appearing or illumination of the "Low Tire" lamp. After checking the vehicle tire pressures, owners have indicated that none of the tires were found to be under inflated 12 psi (53 kPa) or more in comparison to the other three assemblies. This condition typically can be duplicated by operating the vehicle over a rough washboard type road surface. Correction Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON > Page 7861 Replace the existing EBCM/EBTCM with a new component selected from the following table. To determine the correct part number to order, locate the ECU PN (1) as shown in figure, on the existing EBCM/EBTCM label. Then refer to the chart to determine the correct service part number. Follow the applicable SI 2000 service procedure indicated by vehicle year and model. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON Electronic Brake Control Module: All Technical Service Bulletins Tire Inflation Monitor - False Message/Lamp ON File In Section: 03 - Suspension Bulletin No.: 01-03-10-008A Date: February, 2002 TECHNICAL Subject: False Tire Inflation Monitor System (TIM) Message/Lamp Illumination (Install New Electronic Brake Traction Control Module - EBTCM) Models: 1999-2001 Buick Century, Regal This bulletin is being revised to add additional Existing ECU Part Numbers. Please discard Corporate Bulletin Number 01-03-1-008 (Section 03-Suspension) Condition Some owners may comment on the "Low Tire Pressure" message appearing or illumination of the "Low Tire" lamp. After checking the vehicle tire pressures, owners have indicated that none of the tires were found to be under inflated 12 psi (53 kPa) or more in comparison to the other three assemblies. This condition typically can be duplicated by operating the vehicle over a rough washboard type road surface. Correction Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON > Page 7867 Replace the existing EBCM/EBTCM with a new component selected from the following table. To determine the correct part number to order, locate the ECU PN (1) as shown in figure, on the existing EBCM/EBTCM label. Then refer to the chart to determine the correct service part number. Follow the applicable SI 2000 service procedure indicated by vehicle year and model. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7868 Electronic Brake Control Module: Specifications Brake Pressure Modulator Valve (BPMV) and Electronic Brake Control Module (EBCM) Assembly to Mounting Bracket 89 in.lb Electronic Brake Control Module (EBCM) to Brake Pressure Modulator Valve (BPMV) 44 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Component Locations > Page 7871 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Electronic Brake Traction Control Module (EBTCM), C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Electronic Brake Traction Control Module (EBTCM), C1 > Page 7874 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 7875 Electronic Brake Control Module: Service and Repair Removal Procedure Notice: To prevent equipment damage, never connect or disconnect the wiring harness connection from the EBCM with the ignition switch in the ON position. 1. Turn the ignition switch to the OFF position. 2. Remove red locking tab from connector lock tab (1). 3. Push down lock tab (1) and then move sliding connector cover (2) to the open position. 4. Disconnect the EBCM harness connector. 5. Brush off any dirt/debris that has accumulated on the assembly. 6. Remove the four EBCM to BPMV screws (1). 7. Separate the EBCM (2) from the BPMV (3) by gently pulling apart until separated. Important: Do not pry apart using a tool. Be careful not to damage BPMV surface. Important: Care must be taken not to damage the solenoid valves when the EBCM is removed from the BPMV. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 7876 1. Clean the BPMV surface with alcohol using a clean rag. 2. Install the EBCM (2) to the BPMV (3). 3. Install the four screws (1) that attaches the EBCM (2) to BPMV (3). Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the four screws to 5 Nm (44 inch lbs.). 4. Connect the EBCM harness connector. 5. Push down lock tab (1) and then move sliding connector cover (2) back in the home position to lock. 6. Insert red locking tab back in place. 7. Turn the ignition switch to the RUN position, do not start engine. 8. Perform the A Diagnostic System Check - ABS. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Fastener Tightening Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Fastener Tightening Specifications Brake Pipe Fittings At Brake Pressure Modulator Valve (BPMV) And Master Cylinder ...................................................................................... 18 ft. lbs. Brake Pressure Modulator Valve (BPMV) and Electronic Brake Control Module (EBCM) Assembly to Mounting Bracket ............................ 89 inch lbs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Fastener Tightening Specifications > Page 7881 Hydraulic Control Assembly - Antilock Brakes: Specifications Component Specifications Modulator Tube Nuts ........................................................................................................................... ................................................................... 11 ft. lbs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 7882 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Modulator Bracket Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Modulator Bracket Replacement Removal Procedure 1. Turn the Ignition switch to the OFF position. 2. Remove the two BPMV mounting bracket nuts (3) and one bolt located near the bottom and one nut (1) located at the top of the BPMV mounting bracket (4) to the strut tower. 3. Disconnect the ground strap between the EBCM assembly and the chassis. 4. Remove the BPMV mounting bracket (4) from the vehicle. 5. Remove BPMV and EBCM assembly (2) from the BPMV mounting bracket (4). Installation Procedure 1. Install the BPMV and EBCM assembly (2) to the BPMV mounting bracket (4). 2. Install the BPMV bracket (4) to the strut tower. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the one bolt and three nuts that attach the BPMV mounting bracket (4) to the strut tower. ^ Tighten the lower two BPMV mounting bracket nuts (3) and bolt to 10 Nm (89 inch lbs.). ^ Tighten the top nut (1) for BPMV mounting bracket (4) to strut tower to 3 Nm (27 inch lbs.). 4. Reconnect the ground strap between the EBCM assembly and the chassis. 5. Turn the ignition switch to the RUN position, engine off. 6. Perform the A Diagnostic System Check - ABS. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Modulator Bracket Replacement > Page 7885 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Removal Procedure Caution: For safety reasons, the Brake Pressure Modulator Valve (BPMV) must not be repaired, the complete unit must be replaced With the exception of the EBCM/EBTCM, no screws may be loosened. if screws are loosened, it will not be possible to get the brake circuits leak-tight and personal injury may result. 1. Turn the ignition switch to the OFF position. 2. Remove the attaching bolts for the cruise control module. 3. Swing the cruise control module off to the side. 4. Disengage the red locking tab from the connector (1). 5. Push down lock tab (1) and then move sliding connector cover (2) to the open position. 6. Disconnect the EBCM harness connector. Important: Note the locations of the brake pipes in order to aid in installation. 7. Disconnect the brake pipes (1) from the BPMV (2). 8. Swing the four brakes pipes out of the way only after covering the open pipes to avoid dripping or being contaminated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Modulator Bracket Replacement > Page 7886 9. Disconnect the master cylinder brake pipes (2) from the BPMV (4). 10. It is not necessary to remove the brake pipes (2) from the master cylinder (1). 11. Swing the two master cylinder brake pipes out of the way only after covering the open pipes to avoid dripping or being contaminated. 12. Remove the two BPMV mounting bracket nuts (3) and one bolt located near the bottom and one nut (1) located at the top of the BPMV mounting bracket (4) to the strut tower. 13. Disconnect the ground strap between the EBCM assembly and the chassis. 14. Remove the BPMV mounting bracket (4) and EBCM assembly (2) from the vehicle. Notice: When removing the brake pressure modulator valve, protect the vehicle exterior from possible brake fluid spillage. Brake fluid can cause damage to painted surfaces. 15. Remove the four bolts (3) that connect the BPMV (1) to the mounting bracket (2). 16. Remove EBCM if replacing the BPMV only. Refer to Electronic Brake Control Module (EBCM) Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Modulator Bracket Replacement > Page 7887 Installation Procedure 1. Install EBCM onto the BPMV (1) if replacing the BPMV only. Refer to Electronic Brake Control Module (EBCM) Replacement. 2. Install BPMV and EBCM as an assembly (1) to the mounting bracket (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the four bolts (3) that connects the BPMV assembly (1) to the mounting bracket (2). ^ Tighten the four bolts (3) that connect the BPMV (1) to the mounting bracket (2) to 10 Nm (89 inch lbs.). 4. Install the BPMV bracket (4) to the strut tower. 5. Install the one bolt and three nuts that attach the BPMV Mounting bracket (4) to the strut tower. ^ Tighten the lower two BPMV mounting bracket nuts (3) and bolt to 10 Nm (84 inch lbs.). ^ Tighten the top nut (1) for BPMV mounting bracket (4) to strut tower to 3 Nm (27 inch lbs.). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Modulator Bracket Replacement > Page 7888 Important: If a new BPMV is being installed, remove the shipping plugs from the valve openings during the next few steps when ready. Caution: Make sure brake pipes are correctly connected to brake pressure modulator valve. If brake pipes are switched by mistake, wheel lockup will occur and personal injury may result. The only two ways this condition can be detected are by using a Scan Tool or by doing an Antilock stop. 6. Install the master cylinder brake pipes (2) into the BPMV (4). ^ Tighten the master cylinder brake pipe fittings to 24 Nm (18 ft. lbs.). 7. Install the brake pipes (1) on the BPMV (2). ^ Tighten all four brake pipe fittings to 24 Nm (18 ft. lbs.). 8. Reconnect the ground strap between the EBCM assembly and the chassis. 9. Connect the EBCM harness connector. 10. Push down lock tab (1) and then move sliding connector cover (2) back in home position to lock. 11. Insert red locking tab back in place. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Modulator Bracket Replacement > Page 7889 12. Reinstall the cruise control module. 13. When all procedures have been completed, the automated ABS bleed procedure is required. Refer to Automated Bleed Procedure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Testing and Inspection Traction Control Indicator Lamp: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Antilock Brakes / Traction Control Systems Testing and Inspection. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > Customer Interest for Traction Control Module: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON Traction Control Module: Customer Interest Tire Inflation Monitor - False Message/Lamp ON File In Section: 03 - Suspension Bulletin No.: 01-03-10-008A Date: February, 2002 TECHNICAL Subject: False Tire Inflation Monitor System (TIM) Message/Lamp Illumination (Install New Electronic Brake Traction Control Module - EBTCM) Models: 1999-2001 Buick Century, Regal This bulletin is being revised to add additional Existing ECU Part Numbers. Please discard Corporate Bulletin Number 01-03-1-008 (Section 03-Suspension) Condition Some owners may comment on the "Low Tire Pressure" message appearing or illumination of the "Low Tire" lamp. After checking the vehicle tire pressures, owners have indicated that none of the tires were found to be under inflated 12 psi (53 kPa) or more in comparison to the other three assemblies. This condition typically can be duplicated by operating the vehicle over a rough washboard type road surface. Correction Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > Customer Interest for Traction Control Module: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON > Page 7901 Replace the existing EBCM/EBTCM with a new component selected from the following table. To determine the correct part number to order, locate the ECU PN (1) as shown in figure, on the existing EBCM/EBTCM label. Then refer to the chart to determine the correct service part number. Follow the applicable SI 2000 service procedure indicated by vehicle year and model. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Control Module: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON Traction Control Module: All Technical Service Bulletins Tire Inflation Monitor - False Message/Lamp ON File In Section: 03 - Suspension Bulletin No.: 01-03-10-008A Date: February, 2002 TECHNICAL Subject: False Tire Inflation Monitor System (TIM) Message/Lamp Illumination (Install New Electronic Brake Traction Control Module - EBTCM) Models: 1999-2001 Buick Century, Regal This bulletin is being revised to add additional Existing ECU Part Numbers. Please discard Corporate Bulletin Number 01-03-1-008 (Section 03-Suspension) Condition Some owners may comment on the "Low Tire Pressure" message appearing or illumination of the "Low Tire" lamp. After checking the vehicle tire pressures, owners have indicated that none of the tires were found to be under inflated 12 psi (53 kPa) or more in comparison to the other three assemblies. This condition typically can be duplicated by operating the vehicle over a rough washboard type road surface. Correction Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Control Module: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON > Page 7907 Replace the existing EBCM/EBTCM with a new component selected from the following table. To determine the correct part number to order, locate the ECU PN (1) as shown in figure, on the existing EBCM/EBTCM label. Then refer to the chart to determine the correct service part number. Follow the applicable SI 2000 service procedure indicated by vehicle year and model. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Component Locations Traction Control Switch: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Component Locations > Page 7912 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Component Locations > Page 7913 Traction Control Switch: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Component Locations > Page 7914 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Component Locations > Page 7915 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 7916 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 7917 Traction Control Switch: Service and Repair REMOVAL PROCEDURE 1. Apply the parking brake, if equipped with column shift. 2. Position the transaxle shift control indicator to 1, if equipped with column shift. 3. Adjust the steering wheel for access. 4. Remove the ignition switch cylinder bezel. 5. Remove the LH instrument panel (IP) fuse block access opening cover. 6. Remove the LH P cluster trim plate screws. 7. Start at the left side of the P cluster trim plate. Grasp the trim plate and carefully pull rearward. Disengage enough IP cluster trim plate retainers in order to easily access the traction control switch. 8. Disconnect the electrical connectors from the traction control switch. 9. Remove the traction control switch from the IP cluster trim plate. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 7918 1. Install the traction control switch to the IP cluster trim plate. 2. Connect the electrical connector to the traction control switch. 3. Carefully press the IP cluster trim plate into the IP trim pad. Make sure all of the retainers are fully engaged. 4. Install the LH IP cluster trim plate screws. Tighten Tighten the IF cluster trim plate screws to 2 N.m (18 lb in). 5. Install the LH instrument panel (IP) fuse block access opening covers. 6. Install the ignition switch cylinder bezel. 7. Return the steering wheel to the original position. 8. Position the transaxle shift control indicator to Park, if equipped with a column shift. 9. Push to release the parking brake, if equipped with column shift. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > LF Wheel Speed Sensor Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > LF Wheel Speed Sensor > Page 7923 Wheel Speed Sensor: Locations Wheel Speed Sensor, Rear In the rear wheel hub(s). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, LF Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, LF > Page 7926 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, LF > Page 7927 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, LF > Page 7928 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (Front) Removal Procedure Important: The front wheel speed sensors and rings are integral with the hub and bearing assemblies. If a speed sensor or a ring needs replacement, replace the entire hub and bearing assembly. Do not service the harness pigtail individually because the harness pigtail is part of the sensor. Refer to Front Wheel Drive Shaft Bearing Replacement. 1. Raise and support the vehicle on a suitable hoist. Refer to Vehicle Lifting. 2. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation. 3. Remove the front wheel speed sensor jumper harness electrical connector (1) from the front wheel speed sensor connector (3). 4. Remove the hub and bearing assembly (2). Refer to Front Wheel Drive Shaft Bearing Replacement for removal. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) > Page 7931 1. Install the hub and bearing assembly (2) to the vehicle. Refer to Front Wheel Drive Shaft Bearing Replacement for installation. 2. Install the front wheel speed sensor jumper harness electrical connector (1) to front wheel speed sensor connector (3). 3. Install the wheel and tire assembly. Refer to Tire and Wheel Removal and Installation. 4. Lower the vehicle. 5. Turn the ignition switch to the RUN position with the engine off. 6. Perform the A Diagnostic System Check - ABS. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) > Page 7932 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (Rear) Removal Procedure Important: The rear wheel speed sensors and rings are integral with the hub and bearing assemblies. If a speed sensor or a ring needs replacement, replace the entire hub and bearing assembly. Refer to Wheel Bearing/Hub Replacement - Rear. 1. Raise and support the vehicle on a suitable hoist. Refer to Vehicle Lifting. 2. Remove the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation. 3. Remove the rear wheel speed sensor electrical connector (1) located next to the rear strut (2). 4. Remove the hub and bearing assembly (1). Refer to Wheel Bearing/Hub Replacement - Rear for removal. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) > Page 7933 1. Install the hub and bearing assembly (1) to the vehicle. Refer to Wheel Bearing/Hub Replacement - Rear for installation. 2. Install the rear wheel speed sensor electrical connector (1). 3. Install the wheel and tire assembly. Refer to Tire and Wheel Removal and Installation. 4. Lower the vehicle. 5. Turn the ignition switch to the RUN position with the engine off. 6. Perform the A Diagnostic System Check ABS. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure Brake Bleeding: Service and Repair Automated Bleed Procedure Important: In most circumstances a base brake bleed is all that is required for most component replacements (such as wheel cylinders, calipers, brake tubes, and master cylinder), except for BPMV replacement. The following automated ABS bleed procedure is required when one of the following actions occur: ^ Manual bleeding at the wheels does not achieve the desired pedal height or feel. ^ BPMV (Brake Pressure Modulator Valve) replacement ^ Extreme loss of brake fluid has occurred. ^ Air ingestion is suspected. If none of the above conditions apply, use standard bleed procedures. Refer to Hydraulic Brake System Bleeding. The auto bleed procedure is used on DBC 7 equipped vehicles. This procedure uses a scan tool to cycle the system solenoid valves and run the pump in order to purge the air from the secondary circuits. These secondary circuits are normally closed off, and are only opened during system initialization at vehicle start up, and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped inside the BPMV to flow out toward the wheel cylinders or calipers where the air can be purged out of the system. Automated Bleed Procedure ^ Tools Required A scan tool - A 35 psi pressure bleeder with the proper master cylinder adapter - Delco Supreme 11 or equivalent Dot 3 brake fluid from a clean, sealed container - A hoist - An unbreakable plastic bleeder bottle equipped with a hose (in order to recover fluid at the wheels) - An assistant, if needed - Suitable safety attire, including safety glasses Preliminary Inspection 1. Inspect the battery for full charge, repair the battery and charging system as necessary. Refer to Battery Charging. 2. Connect a scan tool to the Data Link Connector (DLC) and select current and history DTCs. Repair any DTCs prior to performing the ABS bleed procedure. 3. Inspect for visual damage and leaks. Repair as needed. Preliminary Setup 1. Raise and support the vehicle on a suitable support. Refer to Vehicle Lifting. 2. Turn the ignition switch to the OFF position. 3. Remove all four tires, if necessary. 4. Connect the pressure bleeding tool according to the manufacturer's instructions. 5. Turn the ignition switch to RUN position, with the engine off. 6. Connect the scan tool and establish communications with the ABS system. 7. Pressurize the bleeding tool to 30 to 35 psi. Performing the Automated Bleed Procedure Notice: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. 1. With the pressure bleeding tool at 30 to 35 psi, and all bleeder screws in closed position, select Automated Bleed Procedure on the scan tool and follow the instructions. 2. The first part of the automated bleed procedure will cycle the pump and front release valves for 1 minute. After the cycling has stopped the scan tool will enter a "cool down" mode and display a 3 minute timer. The auto bleed will not continue until this timer expired, and cannot be overridden. 3. During the next step, the scan tool will request the technician to open one of the bleeder screws. The scan tool will then cycle the respective release valve and pump motor for 1 minute. 4. The scan tool will repeat step 3 for the remaining bleeder screws. 5. With the bleeder tool still attached to the vehicle and maintaining 35 psi, the scan tool will instruct the technician to independently open each bleeder screw for approximately 20 seconds. This should allow any remaining air to be purged from the brake lines. 6. When the automated bleed procedure is completed, the scan tool will display the appropriate message. 7. Remove pressure from the pressure bleeding tool, and then disconnect the tool from the vehicle. 8. Depress the brake pedal in order to gauge the pedal height and feel. Repeat step 1 through step 8 until the pedal height and feel is acceptable. 9. Remove the scan tool from the DLC connector. 10. Install the tire and wheels assemblies, if removed. 11. Lower the vehicle. 12. Inspect the brake fluid level in master cylinder. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 7938 13. Road test the vehicle in order to ensure that the brake pedal remains high and firm. If vehicle is equipped with TCS, the scan tool will cycle both the ABS and TCS solenoids valves. This bleed procedure is the same as the procedure above. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 7939 Brake Bleeding: Service and Repair Manual and Pressure Bleeding Procedures Caution: Do not move the vehicle until a firm brake pedal is obtained. Air in the brake system can cause loss of brakes with possible personal injury. Caution: Use only SUPREME II or equivalent DOT 3 brake fluid from a clean, sealed container. Do not use fluid from an open container that may be contaminated with water. Improper or contaminated fluid will result in damage to components or loss of braking, with possible personal injury. Caution: Do not overfill the brake fluid reservoir. Overfilling the brake fluid reservoir may cause the brake fluid to overflow onto the engine exhaust components during brake system service. The brake fluid is flammable and may cause a fire and personal injury if the brake fluid contacts the engine exhaust system components. Notice: If any brake component is repaired or replaced such that air is allowed to enter the brake system, the entire bleeding procedure must be followed. Notice: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring, cables, or electric connectors. Brake fluid will damage the paint and the electrical connections. If any fluid is spilled on the vehicle, flush the area to lessen the damage. Notice: Prior to bleeding the brakes, the front and rear displacement cylinder pistons must be returned to the topmost position, The preferred method uses a Scan Tool to perform the rehorning procedure. If a Scan Tool is not available, the second procedure may be used, but it is extremely important that the procedure be followed exactly as outlined. A bleeding operation is necessary in order to remove air when air is introduced into the hydraulic brake system. Bleed the hydraulic system at all four brakes if air has been introduced through a low fluid level or by disconnecting brake pipes at the master cylinder. If a brake hose or brake pipe is disconnected at one wheel, bleed only that one wheel caliper. If brake pipes or hoses are disconnected at any fitting located between the master cylinder and the brakes, then only bleed the brake system served by the disconnected pipe or hose. With Scan Tool (Preferred Method) Refer to Automated Bleed Procedure. Without Scan Tool Notice: This method can only be used if the amber ABS warning indicator is not illuminated and no DTCs are present. Important: Do not place your foot on the brake pedal through this entire procedure unless specifically directed to do so. 1. Remove foot from the brake pedal. 2. Start the engine. Allow the engine to run for at least ten seconds while observing the amber ABS warning indicator. 3. If the amber ABS warning indicator turns on and stays on after ten seconds, stop the bleeding procedure. Use a Scan Tool in order to diagnose the ABS malfunction. 4. If the amber ABS warning indicator turns on for approximately three seconds, then turns off and stays off, turn the ignition off. 5. Repeat the previous four steps one more time. 6. Bleed the entire brake system. Pressure Bleeding ^ Tools Required J 29532 Diaphragm Type Brake Bleeder Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 7940 - J 35589 Compact Brake Bleeder Adapter Notice: Pressure bleeding equipment must be of the diaphragm type. It must have a rubber diaphragm between the air supply and the brake fluid to prevent air, moisture, and other contaminants from entering the hydraulic system. 1. Inspect and fill the master cylinder reservoir to the proper level as necessary. 2. Assemble the components as shown. 3. Install the J 35589 to the master cylinder reservoir. 4. Connect the J 29532 to the J 35589. 5. Adjust the J 29532 to 35 - 70 kPa (5 - 10 psi). 6. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing brake fluid leaks. Repair any brake fluid leaks. 7. Adjust the J 29532 to 205 - 240 kPa (30 - 35 psi). Important: Use a shop cloth in order to catch escaping brake fluid. 8. Slowly open the ABS modulator brake pipe fitting (1) starting from the first pipe on the left side in order to allow the brake fluid to flow. Notice: Refer to Fastener Notice in Service Precautions. 9. Close the ABS modulator brake pipe fitting when air bubbles are no longer detected in the brake fluid. ^ Tighten the ABS modulator brake pipe fitting to 24 Nm (18 ft. lbs.). 10. Repeat Steps 8 and 9 for the remaining ABS modulator brake pipe fittings. 11. Raise and suitably support the vehicle. 12. Install the clear plastic bleeder hose to the RIGHT REAR bleeder valve: ^ For vehicles with rear drum brakes, install the clear plastic bleeder hose to the wheel cylinder bleeder valve. ^ For vehicles with rear disc brakes, install the clear plastic bleeder hose to the brake caliper bleeder valve. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 7941 13. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 14. Slowly open the bleeder valve in order to allow the brake fluid to flow. 15. Close the bleeder valve when air bubbles are no longer detected in the brake fluid. ^ For vehicles with rear drum brakes, tighten the wheel cylinder bleeder valve to 7 Nm (62 inch lbs.). ^ For vehicles with rear disc brakes, tighten the wheel cylinder bleeder valve to 11 Nm (97 inch lbs.) 16. Remove the clear plastic bleeder hose from the bleeder valve. 17. Install the clear plastic bleeder hose to the LEFT FRONT brake caliper bleeder valve. 18. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 19. Slowly open the bleeder valve in order to allow the brake fluid to flow. 20. Close the bleeder valve when air bubbles are no longer detected in the brake fluid. ^ Tighten the brake caliper bleeder valve to 13 Nm (115 inch lbs.). 21. Remove the clear plastic bleeder hose from the bleeder valve. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 7942 22. Install the clear plastic bleeder hose to the LEFT REAR bleeder valve. ^ For vehicles with rear drum brakes, install the clear plastic bleeder hose to the wheel cylinder bleeder valve. ^ For vehicles with rear disc brakes, install the clear plastic bleeder hose to the brake caliper bleeder valve. 23. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 24. Slowly open the bleeder valve in order to allow the brake fluid to flow. 25. Close the bleeder valve when air bubbles are no longer detected in the brake fluid. ^ For vehicles with rear drum brakes, tighten the wheel cylinder bleeder valve to 7 Nm (62 inch lbs.). ^ For vehicles with rear disc brakes, tighten the wheel cylinder bleeder valve to 11 Nm (97 inch lbs.) 26. Remove the clear plastic bleeder hose from the bleeder valve. 27. Install the clear plastic bleeder hose to the RIGHT FRONT brake caliper bleeder valve. 28. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 29. Slowly open the bleeder valve in order to allow the brake fluid to flow. 30. Close the bleeder valve when air bubbles are no longer detected in the brake fluid. ^ Tighten the brake caliper bleeder valve to 13 Nm (115 inch lbs.). 31. Remove the clear plastic bleeder hose from the bleeder valve. 32. Lower the vehicle. 33. Remove the J 35589 from the master cylinder reservoir. 34. Inspect and fill the master cylinder reservoir to the proper level as necessary. Refer to Master Cylinder Reservoir Filling. 35. Install the master cylinder reservoir cap. 36. Start the engine and allow the engine to run for at least 10 seconds. 37. Turn the ignition OFF. 38. Inspect the brake pedal feel and the brake pedal travel. Refer to Brake Pedal Travel. ^ If the brake pedal feels firm and constant and the brake pedal travel does not exceed specifications, proceed to Step 39. ^ If the pedal feels soft or the brake pedal travel exceeds specifications, DO NOT DRIVE THE VEHICLE. Go to Step 40. 39. Start the engine and inspect the brake pedal feel. ^ If the brake pedal still feels firm, got to Step 42. ^ If the brake pedal feels soft, DO NOT DRIVE THE VEHICLE. proceed to Step 40. 40. Use the scan tool in order to perform the automated bleed procedure. Refer to Automated Bleed Procedure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 7943 41. Ensure that the unacceptable brake pedal feel/travel is not caused by misadjusted brake linings or other mechanical failures, then repeat the Brake System Pressure Bleeding procedure. Proceed to Step 1. Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury. 42. Road test the vehicle. Make several normal (non-ABS) stops from a moderate speed in order to ensure proper brake system function. Allow adequate brake system cooling time between stops. Brake System Manual Bleeding Procedure Notice: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring, cables, or electric connectors. Brake fluid will damage the paint and the electrical connections. It any fluid is spilled on the vehicle, flush the area to lessen the damage. Important: This procedure may require the help of an assistant to apply the brake pedal while the bleeder valves are opened and closed. Important: Ensure that the master cylinder brake fluid level does not drop to the bottom of the master cylinder reservoir. You will be instructed to Inspect and fill the master cylinder reservoir at times during this procedure. However, the actual frequency of master cylinder reservoir filling REQUIRED will depend on the amount of fluid that is released. If the brake fluid level drops to the bottom of the master cylinder reservoir, start the bleed procedure again at Step 1. 1. Inspect and fill the master cylinder reservoir to the proper level as necessary. Refer to Master Cylinder Reservoir Filling. Important: Use a shop cloth in order to catch escaping brake fluid. 2. Slowly open the ABS modulator brake pipe fitting (1) starting from the first pipe on the left side in order to allow the brake fluid to flow. 3. Press and hold the brake pedal approximately 75 percent of a full stroke. Notice: Refer to Fastener Notice in Service Precautions. 4. Close the ABS modulator brake pipe fitting when air bubbles are no longer detected in the brake fluid. ^ Tighten the ABS modulator brake pipe fitting to 24 Nm (18 ft. lbs.). 5. Repeat Steps 2 and 3 for the remaining ABS modulator brake pipe fittings. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 7944 6. Inspect and fill the master cylinder reservoir to the proper level as necessary. 7. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 8. Install the clear plastic bleeder hose to the RIGHT REAR bleeder valve. ^ For vehicles with rear drum brakes, install the clear plastic bleeder hose to the wheel cylinder bleeder valve. ^ For vehicles with rear disc brakes, install the clear plastic bleeder hose to the brake caliper bleeder valve. 9. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 10. Open the bleeder valve. 11. Press and hold the brake pedal approximately 75 percent of a full stroke. 12. Close the bleeder valve. 13. Release the brake pedal. 14. Repeat Steps 10 through 13 until air bubbles are no longer detected in the brake fluid. ^ For vehicles with rear drum brakes, tighten the wheel cylinder bleeder valve to 7 Nm (62 inch lbs.). ^ For vehicles with rear disc brakes, tighten the wheel cylinder bleeder valve to 11 Nm (97 inch lbs.) 15. Remove the clear plastic bleeder hose from the bleeder valve. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 7945 16. Install the clear plastic bleeder hose to the LEFT FRONT brake caliper bleeder valve. 17. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 18. Open the bleeder valve. 19. Press and hold the brake pedal approximately 75 percent of a full stroke. 20. Close the bleeder valve. 21. Release the brake pedal. 22. Repeat Steps 18 through 21 until air bubbles are no longer detected in the brake fluid. ^ Tighten the brake caliper bleeder valve to 13 Nm (115 inch lbs.). 23. Remove the clear plastic bleeder hose from the bleeder valve. 24. Install the clear plastic bleeder hose to the LEFT REAR bleeder valve. ^ For vehicles with rear drum brakes, install the clear plastic bleeder hose to the wheel cylinder bleeder valve. ^ For vehicles with rear disc brakes, install the clear plastic bleeder hose to the brake caliper bleeder valve. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 7946 25. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 26. Open the bleeder valve. 27. Press and hold the brake pedal approximately 75 percent of a full stroke. 28. Close the bleeder valve. 29. Release the brake pedal. 30. Repeat Steps 26 through 29 until air bubbles are no longer detected in the brake fluid. ^ For vehicles with rear drum brakes, tighten the wheel cylinder bleeder valve to 7 Nm (62 inch lbs.). ^ For vehicles with rear disc brakes, tighten the wheel cylinder bleeder valve to 11 Nm (97 inch lbs.). 31. Remove the clear plastic bleeder hose from the bleeder valve. 32. Install the clear plastic bleeder hose to the RIGHT FRONT brake caliper bleeder valve. 33. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 34. Open the bleeder valve. 35. Press and hold the brake pedal approximately 75 percent of a full stroke. 36. Close the bleeder valve. 37. Release the brake pedal. 38. Repeat Steps 34 through 37 until air bubbles are no longer detected in the brake fluid. ^ Tighten the brake caliper bleeder valve to 13 Nm (115 inch lbs.). 39. Remove the clear plastic bleeder hose from the bleeder valve. 40. Lower the vehicle. 41. Remove the brake fluid reservoir cover. 42. Inspect the brake fluid level in the reservoir. 43. Install the brake fluid reservoir cover. 44. Turn the ignition switch to the RUN position, then turn off the engine. Apply the brake pedal with moderate force and hold the pedal. Note the pedal travel and feel. 45. If the pedal feels firm and constant and pedal travel is not excessive, start the engine. With the engine running, recheck the pedal travel. 46. If the pedal feel is still firm and constant and pedal travel is not excessive, perform a vehicle road test. Make several normal (non-ABS) stops from a moderate speed in order to ensure proper brake system function. 47. If pedal feel is soft or has excessive travel either initially or after engine start, refer to Automated Bleed Procedure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 7947 48. Repeat the manual bleeding procedure, starting at Step 1. Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury. 49. Perform a vehicle road test. Make several normal (non-ABS) stops from a moderate speed in order to ensure proper brake system function. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Fastener Tightening Specifications Brake Pedal Assy: Specifications Brake Pedal racket Lower Mounting Bolts 16 ft.lb Brake Pedal Bracket Upper Mounting Bolts 18 ft.lb Brake Pedal Bolt and Nut 30 ft.lb Brake Pedal Reinforcement Bracket Nuts 37 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Fastener Tightening Specifications > Page 7952 Brake Pedal Assy: Specifications Brake Pedal Bracket Lower Mounting Bolts 16 ft.lb Brake Pedal Bracket Upper Mounting Bolts 18 ft.lb Brake Pedal Bolt 30 ft.lb Brake Pedal Reinforcement Bracket Nuts 37 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Fastener Tightening Specifications > Page 7953 Brake Pedal Assy: Specifications Brake Pedal Travel 2.91 in Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 7954 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal Bracket Replacement Brake Pedal Assy: Service and Repair Brake Pedal Bracket Replacement Removal Procedure 1. Remove the brake booster. 2. Remove the brake pedal bracket mounting nuts. 3. Remove the Cross Vehicle Beam. 4. Remove the brake pedal. Refer to Brake Pedal Replacement. 5. Remove the brake pedal bracket Installation Procedure 1. Install the brake pedal bracket. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal Bracket Replacement > Page 7957 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the brake pedal bracket mounting nuts. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). 3. Install the brake pedal. Refer to Brake Pedal Replacement. 4. Install the Cross Vehicle Beam. 5. Install the brake booster. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal Bracket Replacement > Page 7958 Brake Pedal Assy: Service and Repair Brake Pedal Replacement Removal Procedure 1. Remove the left instrument panel insulator. 2. Uncap the BCM and position aside. 3. Remove the stoplamp switch. Refer to Stoplamp Switch Replacement 4. Remove the cruise release switch (if equipped). Refer to Cruise Release Switch Replacement. 5. Remove the wiring harness clips 6. Remove the brake pedal pushrod retaining clip. 7. Remove the brake pedal pushrod and washer. 8. Inspect all parts for evidence of wear. Repair or replace the worn parts as needed. 9. Remove the brake pedal bolt and nut. 10. Remove the brake pedal and bushings. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal Bracket Replacement > Page 7959 1. Install the brake pedal and the bushings. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the brake pedal bolt and nut. ^ Tighten the bolts to 40 Nm (30 ft. lbs.). 3. Install the brake pedal washer and pushrod. 4. Install the brake pedal pushrod retaining clip. 5. Install the wiring harness clips 6. Install the cruise release switch (if equipped). Refer to Cruise Release Switch Replacement. 7. Install the stoplamp switch. Refer to Stoplamp Switch Replacement. 8. Position and clip the BCM back into place. 9. Install the left instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal Bracket Replacement > Page 7960 Brake Pedal Assy: Service and Repair Brake Pedal Push Rod Boot Retainer Replacement Removal Procedure 1. Remove the brake pedal reinforcement bracket. Refer to Brake Pedal Bracket Replacement. 2. Remove the brake pedal push rod boot from the retainer. 3. Inspect all of the parts for wear. Repair or replace the parts as needed. Installation Procedure 1. Install the brake pedal push rod boot to the retainer. 2. Install the brake pedal reinforcement bracket. Refer to Brake Pedal Bracket Replacement. 3. Adjust the stoplamp switch. Refer to Stoplamp Switch Adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Testing and Inspection Brake Warning Indicator: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Hydraulic System Testing and Inspection. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest: > 01-05-23-011A > Feb > 02 > Brakes - Rattling Noise Brake Caliper: Customer Interest Brakes - Rattling Noise File In Section: 05 - Brakes Bulletin No.: 01-05-23-O11A Date: February, 2002 TECHNICAL Subject: Rattle Type Noise Coming from Front of Vehicle (Install Front Brake Caliper Service Kit) Models: 2000-01 Buick Century, Regal 2000-01 Chevrolet Impala, Monte Carlo, Venture 2000-01 Oldsmobile Intrigue, Silhouette 2000-01 Pontiac Grand Prix, Montana This bulletin is being revised to remove Chevrolet Lumina from the Models section and to update the condition information. Please discard Corporate Bulletin Number 01-05-23-11 (Section 05 Brakes). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment about a rattle type noise coming from the front of the vehicle. This noise usually occurs at vehicle speeds under 48 km/h (30 mph) and while driving over bumps. The noise can usually be eliminated by a light application of the brake pedal. Cause This condition may be caused by too much clearance between the front brake caliper bracket and the caliper pins in the bottom of the bracket bores. Correction Install front brake caliper service kits to both sides of the vehicle using the following service procedure. Each kit contains 2 pins, 2 boots, and 2 packets of grease. Service Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove both the front tire and wheel assemblies. 3. Hand tighten 2 wheel nuts to retain the rotor to the hub. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest: > 01-05-23-011A > Feb > 02 > Brakes - Rattling Noise > Page 7973 4. Install a large C-clamp (2) over the top of the brake caliper and against the back of the outboard brake pad. 5. Tighten the C-clamp until the caliper piston is pushed into the caliper bore enough to slide the caliper off the rotor. 6. Remove the C-clamp from the caliper. 7. Remove the caliper pin bolts (3) and discard. New bolts are supplied with the service kit. 8. Remove the caliper (1) from the caliper bracket (2) and support the caliper with heavy mechanic's wire, or equivalent. 9. Using a flat bladed tool or punch, carefully tap the caliper pin boots from the brake caliper bracket and discard. 10. Remove and discard the bushings from the brake caliper bracket bores. Carefully insert a small screwdriver into the brake caliper bracket bore, then rotate and pull the bushing outward to remove. 11. Remove the brake pads from the brake caliper bracket. 12. Thoroughly clean the brake caliper bracket bores of all lubricant. 13. Install the brake pads to the brake caliper bracket. 14. Lubricate the brake caliper bracket bores. Divide the large packet of grease, P/N 18046532; put one-half packet into each bore. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest: > 01-05-23-011A > Feb > 02 > Brakes - Rattling Noise > Page 7974 15. Lubricate the new caliper pin boots. Use the small packet of grease, P/N 18046645, only on the bottom internal threads (2). 16. Install the new caliper pin boots into the caliper pin bores (3) on the bracket. Carefully tap boots into bores using a deep well socket or equivalent. 17. Install the caliper over the rotor and onto the caliper bracket. Ensure that the caliper pin boots are not pinched. Important: The leading caliper pin, or top pin, has a bushing as part of the assembly. The trailing caliper pin, or bottom pin, is a solid design. 18. Install the new caliper pin bolts (1). It is important to note which caliper pin is designed for the correct bore. The leading caliper pin, or top pin, has a bushing as part of the assembly. The trailing caliper pin, or bottom pin, is a solid design. Ensure that the bolt boots fit securely in the groove of the pin bolts. Be sure not to pinch or tear the boots. If the boots are damaged, they must be replaced. Tighten Tighten the bolts to 95 N.m (70 lb ft). 19. Remove the 2 wheel nuts retaining the rotor to the hub. 20. Repeat the above steps for the other side. 21. Install both the front tire and wheel assemblies. Tighten the wheel nuts using the J 39544 kit. 22. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest: > 01-05-23-011A > Feb > 02 > Brakes - Rattling Noise > Page 7975 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-05-23-011A > Feb > 02 > Brakes - Rattling Noise Brake Caliper: All Technical Service Bulletins Brakes - Rattling Noise File In Section: 05 - Brakes Bulletin No.: 01-05-23-O11A Date: February, 2002 TECHNICAL Subject: Rattle Type Noise Coming from Front of Vehicle (Install Front Brake Caliper Service Kit) Models: 2000-01 Buick Century, Regal 2000-01 Chevrolet Impala, Monte Carlo, Venture 2000-01 Oldsmobile Intrigue, Silhouette 2000-01 Pontiac Grand Prix, Montana This bulletin is being revised to remove Chevrolet Lumina from the Models section and to update the condition information. Please discard Corporate Bulletin Number 01-05-23-11 (Section 05 Brakes). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment about a rattle type noise coming from the front of the vehicle. This noise usually occurs at vehicle speeds under 48 km/h (30 mph) and while driving over bumps. The noise can usually be eliminated by a light application of the brake pedal. Cause This condition may be caused by too much clearance between the front brake caliper bracket and the caliper pins in the bottom of the bracket bores. Correction Install front brake caliper service kits to both sides of the vehicle using the following service procedure. Each kit contains 2 pins, 2 boots, and 2 packets of grease. Service Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove both the front tire and wheel assemblies. 3. Hand tighten 2 wheel nuts to retain the rotor to the hub. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-05-23-011A > Feb > 02 > Brakes - Rattling Noise > Page 7981 4. Install a large C-clamp (2) over the top of the brake caliper and against the back of the outboard brake pad. 5. Tighten the C-clamp until the caliper piston is pushed into the caliper bore enough to slide the caliper off the rotor. 6. Remove the C-clamp from the caliper. 7. Remove the caliper pin bolts (3) and discard. New bolts are supplied with the service kit. 8. Remove the caliper (1) from the caliper bracket (2) and support the caliper with heavy mechanic's wire, or equivalent. 9. Using a flat bladed tool or punch, carefully tap the caliper pin boots from the brake caliper bracket and discard. 10. Remove and discard the bushings from the brake caliper bracket bores. Carefully insert a small screwdriver into the brake caliper bracket bore, then rotate and pull the bushing outward to remove. 11. Remove the brake pads from the brake caliper bracket. 12. Thoroughly clean the brake caliper bracket bores of all lubricant. 13. Install the brake pads to the brake caliper bracket. 14. Lubricate the brake caliper bracket bores. Divide the large packet of grease, P/N 18046532; put one-half packet into each bore. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-05-23-011A > Feb > 02 > Brakes - Rattling Noise > Page 7982 15. Lubricate the new caliper pin boots. Use the small packet of grease, P/N 18046645, only on the bottom internal threads (2). 16. Install the new caliper pin boots into the caliper pin bores (3) on the bracket. Carefully tap boots into bores using a deep well socket or equivalent. 17. Install the caliper over the rotor and onto the caliper bracket. Ensure that the caliper pin boots are not pinched. Important: The leading caliper pin, or top pin, has a bushing as part of the assembly. The trailing caliper pin, or bottom pin, is a solid design. 18. Install the new caliper pin bolts (1). It is important to note which caliper pin is designed for the correct bore. The leading caliper pin, or top pin, has a bushing as part of the assembly. The trailing caliper pin, or bottom pin, is a solid design. Ensure that the bolt boots fit securely in the groove of the pin bolts. Be sure not to pinch or tear the boots. If the boots are damaged, they must be replaced. Tighten Tighten the bolts to 95 N.m (70 lb ft). 19. Remove the 2 wheel nuts retaining the rotor to the hub. 20. Repeat the above steps for the other side. 21. Install both the front tire and wheel assemblies. Tighten the wheel nuts using the J 39544 kit. 22. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-05-23-011A > Feb > 02 > Brakes - Rattling Noise > Page 7983 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-05-23-006A > Jun > 01 > Brake Calipers Revised Fastener Requirements Brake Caliper: All Technical Service Bulletins Brake Calipers - Revised Fastener Requirements File In Section: 05 - Brakes Bulletin No.: 01-05-23-006A Date: June, 2001 SERVICE MANUAL UPDATE Subject: Revised Fastener Requirements for Front and Rear Brake Caliper Bracket Replacement Models: 1997-2001 Buick Century, Regal 1997-2001 Buick Regal (Export China) 1997-2001 Chevrolet Trans Sport (Export China), Venture 2000-2001 Chevrolet Impala, Monte Carlo 1998-2001 Oldsmobile Intrigue 1997-1998 Pontiac Trans Sport 1997-2001 Pontiac Grand Prix 1999-2001 Pontiac Montana This bulletin is being revised to update the model information. Please discard Corporate Bulletin Number 01-05-23-006 (Section 05 - Brakes). This bulletin is being issued to revise the fastener requirements for the front and rear brake caliper bracket replacement procedures in the Disc-Brake sub-section of Brakes in the appropriate Service Manual. Please use the following to replace the existing information in the Service Manual. This information has been updated within SI2000. If you are using a paper version of this Service Manual, please mark a reference to this bulletin on the affected page in the Disc-Brake sub-section of the Service Manual. Front Brake Caliper Bracket Replacement (All Above Listed Vehicles) 1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanics wire or equivalent. It is not necessary to disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the front brake pads. 3. Remove the caliper bracket bolts (2). 4. Remove the caliper bracket (1). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-05-23-006A > Jun > 01 > Brake Calipers Revised Fastener Requirements > Page 7988 Important: To ensure that the proper clamp load will be present when installed, it is imperative that the threads on the caliper bracket bolts, as well as the mounting holes in the knuckle, be cleaned of all debris and inspected before proceeding with installation. 5. Clean and visually inspect threads of the caliper bracket bolts (2) and mounting holes in the knuckle. 6. Apply LOCTITE(R) THREAD LOCKER 272 (GM P/N 12345493) or equivalent to the threads of the brake caliper bracket bolts (2). 7. Install the caliper bracket (1) with the bracket bolts (2). Tighten Tighten the caliper bracket bolts to 180 N.m (133 lb ft). 8. Install the front brake pads. 9. Install the caliper. Rear Brake Caliper Bracket Replacement (See Vehicles Listed Below) ^ 1999-2001 Buick Century, Regal ^ 1999-2001 Buick Regal (Export China) ^ 2000-2001 Chevrolet Impala, Monte Carlo ^ 2000-2001 Chevrolet Trans Sport (Export China) ^ 1998-2001 Oldsmobile Intrigue ^ 1997-2001 Pontiac Grand Prix 1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanics wire or equivalent. It is not necessary to disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the rear brake pads. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-05-23-006A > Jun > 01 > Brake Calipers Revised Fastener Requirements > Page 7989 3. Remove the caliper bracket bolts (2). 4. Remove the caliper bracket (1). Important: To ensure that the proper clamp load will be present when installed, it is imperative that the threads on the caliper bracket bolts, as well as the mounting holes in the knuckle, be cleaned of all debris and inspected before proceeding with installation. 5. Clean and visually inspect threads of the caliper bracket bolts (2) and mounting holes in the knuckle. 6. Apply LOCTITE(R) THREAD LOCKER 272 (GM P/N 12345493) or equivalent to the threads of the brake caliper bracket bolts (2). 7. Install the caliper bracket (1) with the bracket bolts (2). Tighten Tighten the caliper bracket bolts to 115 N.m (85 lb ft). 8. Install the rear brake pads. 9. Install the caliper. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-05-23-003 > Mar > 01 > Front/Rear Brakes - Revised Tool Requirements Technical Service Bulletin # 01-05-23-003 Date: 010301 Front/Rear Brakes - Revised Tool Requirements File In Section: 05 - Brakes Bulletin No.: 01-05-23-003 Date: March, 2001 SERVICE MANUAL UPDATE Subject: Revised Tool Requirements for Front and Rear Brake Caliper Overhaul Models: 1997-2001 Buick Park Avenue, Regal 1997-2001 Buick Regal (Export China) 2000-2001 Buick LeSabre 1997-2001 Cadillac DeVille, Seville 2000-2001 Cadillac Eldorado 1997-2001 Chevrolet Trans Sport (Export China), Venture 2000-2001 Chevrolet Impala, Lumina, Monte Carlo 1997-2001 Oldsmobile Aurora, Silhouette 1998-2001 Oldsmobile Intrigue 1997-2001 Pontiac Grand Prix, Montana, Trans Sport 2000-2001 Pontiac Bonneville This bulletin is being issued to revise the tool requirements for the front and rear brake caliper overhaul procedures in the Disc-Brake sub-section of Brakes in the appropriate Service Manual. Please use the following to replace the existing information in the Service Manual. This information has been updated within SI2000. If you are using a paper version of this Service Manual, please mark a reference to this bulletin on the affected page in the Disc Brake sub-section of the Service Manual. DISCLAIMER Front Brake Caliper Overhaul Procedure (All Above Listed Vehicles) Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury. Notice: Use clean cloths to pad the interior of the caliper housing during piston removal. Use just enough air to ease the piston out of the bores. If the pistons are blown out, even with the padding provided it may be damaged. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-05-23-003 > Mar > 01 > Front/Rear Brakes - Revised Tool Requirements > Page 7994 1. Remove the front brake caliper from the vehicle. 2. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole. 3. Using a small wooden or plastic tool, remove the caliper piston seal (2) from the seal counterbore in the caliper (1) and discard the boot seal. 4. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore and discard the piston seal. 5. Remove the bleeder valve (5) and cap (6) from the caliper (1). Important: Do not use abrasives to clean the brake caliper piston. 6. Clean the brake caliper piston bore and seal counterbore and the caliper piston with denatured alcohol, or equivalent. 7. Dry the caliper piston bore and counterbore and the piston with non-lubricated, filtered air. 8. Inspect the caliper bore for cracks, scoring, pitting, excessive rust and/or excessive corrosion. 9. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 10. If cracks, scoring, pitting, excessive rust and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 11. Inspect the caliper piston for cracks, scoring and/or damage to the finished surface area. Replace the caliper piston if any of these conditions exist. 12. Lubricate the new piston seal with Delco Supreme 11(R), P/N 12377967 (in Canada use P/N 992668), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 13. Install the lubricated new piston seal into the caliper bore. 14. Install the caliper piston into the caliper bore. Press the piston to the bottom of the bore. 15. Install the new piston dust boot seal over the piston. 16. Use J-35777 to fully seat the caliper piston seal into the counterbore. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-05-23-003 > Mar > 01 > Front/Rear Brakes - Revised Tool Requirements > Page 7995 17. Install the bleeder valve and cap to the caliper and tighten the valve securely. 18. Install the front brake caliper to the vehicle. Rear Brake Caliper Overhaul Procedure (See Vehicles Listed Below) ^ 1999-2001 Buick Regal ^ 1999-2001 Buick Regal (Export China) ^ 2000-2001 Chevrolet Impala, Monte Carlo, Trans Sport (Export China) ^ 1998-2001 Oldsmobile Intrigue ^ 1997-2001 Pontiac Grand Prix Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury. Notice: Use clean cloths to pad the interior of the caliper housing during piston removal. Use just enough air to ease the piston out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. 1. Remove the rear brake caliper from the vehicle. 2. Remove the bleeder valve and cap from the caliper housing. 3. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole. 4. Remove the retaining ring that secures the dust boot to the caliper housing. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-05-23-003 > Mar > 01 > Front/Rear Brakes - Revised Tool Requirements > Page 7996 5. Remove the piston dust boot seal (2) from the seal counterbore in the caliper. Discard the boot seal. 6. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore. Discard the piston seal. Important: Do not use abrasives to clean the brake caliper piston. 7. Clean the brake caliper piston bore and seal counterbore and the caliper piston with denatured alcohol, or equivalent. 8. Dry the caliper piston bore and counterbore and the piston with non-lubricated, filtered air. 9. Inspect the caliper bore for cracks, scoring, pitting, excessive rust and/or excessive corrosion. 10. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 11. If cracks, scoring, pitting, excessive rust and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 12. Inspect the caliper piston for cracks, scoring and/or damage to the chrome plating. Replace the caliper piston if any of these conditions exist. 13. Lubricate the new piston seal (4) with Delco Supreme 11(R), P/N 12377967 (in Canada, use P/N 992668), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Install the lubricated new piston seal (4) into the caliper bore. 15. Install the bottom half of the caliper piston (3) into the caliper bore. 16. Install the new piston dust boot seal (2) over the caliper piston (3). 17. Compress the caliper piston (3) to the bottom of the caliper bore. 18. Fully seat the piston dust boot seal (2) into caliper counterbore. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-05-23-003 > Mar > 01 > Front/Rear Brakes - Revised Tool Requirements > Page 7997 19. Install the retaining ring that secures the dust boot to the caliper housing. 20. Install the bleeder valve and cap to the caliper and tighten the valve securely. 21. Install the rear brake caliper to the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON Traction Control Module: All Technical Service Bulletins Tire Inflation Monitor - False Message/Lamp ON File In Section: 03 - Suspension Bulletin No.: 01-03-10-008A Date: February, 2002 TECHNICAL Subject: False Tire Inflation Monitor System (TIM) Message/Lamp Illumination (Install New Electronic Brake Traction Control Module - EBTCM) Models: 1999-2001 Buick Century, Regal This bulletin is being revised to add additional Existing ECU Part Numbers. Please discard Corporate Bulletin Number 01-03-1-008 (Section 03-Suspension) Condition Some owners may comment on the "Low Tire Pressure" message appearing or illumination of the "Low Tire" lamp. After checking the vehicle tire pressures, owners have indicated that none of the tires were found to be under inflated 12 psi (53 kPa) or more in comparison to the other three assemblies. This condition typically can be duplicated by operating the vehicle over a rough washboard type road surface. Correction Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON > Page 8003 Replace the existing EBCM/EBTCM with a new component selected from the following table. To determine the correct part number to order, locate the ECU PN (1) as shown in figure, on the existing EBCM/EBTCM label. Then refer to the chart to determine the correct service part number. Follow the applicable SI 2000 service procedure indicated by vehicle year and model. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-03-10-008A > Feb > 02 > All Technical Service Bulletins for Brake Caliper: > 01-05-23-011A > Feb > 02 > Brakes - Rattling Noise Brake Caliper: All Technical Service Bulletins Brakes - Rattling Noise File In Section: 05 - Brakes Bulletin No.: 01-05-23-O11A Date: February, 2002 TECHNICAL Subject: Rattle Type Noise Coming from Front of Vehicle (Install Front Brake Caliper Service Kit) Models: 2000-01 Buick Century, Regal 2000-01 Chevrolet Impala, Monte Carlo, Venture 2000-01 Oldsmobile Intrigue, Silhouette 2000-01 Pontiac Grand Prix, Montana This bulletin is being revised to remove Chevrolet Lumina from the Models section and to update the condition information. Please discard Corporate Bulletin Number 01-05-23-11 (Section 05 Brakes). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment about a rattle type noise coming from the front of the vehicle. This noise usually occurs at vehicle speeds under 48 km/h (30 mph) and while driving over bumps. The noise can usually be eliminated by a light application of the brake pedal. Cause This condition may be caused by too much clearance between the front brake caliper bracket and the caliper pins in the bottom of the bracket bores. Correction Install front brake caliper service kits to both sides of the vehicle using the following service procedure. Each kit contains 2 pins, 2 boots, and 2 packets of grease. Service Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove both the front tire and wheel assemblies. 3. Hand tighten 2 wheel nuts to retain the rotor to the hub. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-03-10-008A > Feb > 02 > All Technical Service Bulletins for Brake Caliper: > 01-05-23-011A > Feb > 02 > Brakes - Rattling Noise > Page 8013 4. Install a large C-clamp (2) over the top of the brake caliper and against the back of the outboard brake pad. 5. Tighten the C-clamp until the caliper piston is pushed into the caliper bore enough to slide the caliper off the rotor. 6. Remove the C-clamp from the caliper. 7. Remove the caliper pin bolts (3) and discard. New bolts are supplied with the service kit. 8. Remove the caliper (1) from the caliper bracket (2) and support the caliper with heavy mechanic's wire, or equivalent. 9. Using a flat bladed tool or punch, carefully tap the caliper pin boots from the brake caliper bracket and discard. 10. Remove and discard the bushings from the brake caliper bracket bores. Carefully insert a small screwdriver into the brake caliper bracket bore, then rotate and pull the bushing outward to remove. 11. Remove the brake pads from the brake caliper bracket. 12. Thoroughly clean the brake caliper bracket bores of all lubricant. 13. Install the brake pads to the brake caliper bracket. 14. Lubricate the brake caliper bracket bores. Divide the large packet of grease, P/N 18046532; put one-half packet into each bore. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-03-10-008A > Feb > 02 > All Technical Service Bulletins for Brake Caliper: > 01-05-23-011A > Feb > 02 > Brakes - Rattling Noise > Page 8014 15. Lubricate the new caliper pin boots. Use the small packet of grease, P/N 18046645, only on the bottom internal threads (2). 16. Install the new caliper pin boots into the caliper pin bores (3) on the bracket. Carefully tap boots into bores using a deep well socket or equivalent. 17. Install the caliper over the rotor and onto the caliper bracket. Ensure that the caliper pin boots are not pinched. Important: The leading caliper pin, or top pin, has a bushing as part of the assembly. The trailing caliper pin, or bottom pin, is a solid design. 18. Install the new caliper pin bolts (1). It is important to note which caliper pin is designed for the correct bore. The leading caliper pin, or top pin, has a bushing as part of the assembly. The trailing caliper pin, or bottom pin, is a solid design. Ensure that the bolt boots fit securely in the groove of the pin bolts. Be sure not to pinch or tear the boots. If the boots are damaged, they must be replaced. Tighten Tighten the bolts to 95 N.m (70 lb ft). 19. Remove the 2 wheel nuts retaining the rotor to the hub. 20. Repeat the above steps for the other side. 21. Install both the front tire and wheel assemblies. Tighten the wheel nuts using the J 39544 kit. 22. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-03-10-008A > Feb > 02 > All Technical Service Bulletins for Brake Caliper: > 01-05-23-011A > Feb > 02 > Brakes - Rattling Noise > Page 8015 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-03-10-008A > Feb > 02 > All Technical Service Bulletins for Brake Caliper: > 01-05-23-006A > Jun > 01 > Brake Calipers - Revised Fastener Requirements Brake Caliper: All Technical Service Bulletins Brake Calipers - Revised Fastener Requirements File In Section: 05 - Brakes Bulletin No.: 01-05-23-006A Date: June, 2001 SERVICE MANUAL UPDATE Subject: Revised Fastener Requirements for Front and Rear Brake Caliper Bracket Replacement Models: 1997-2001 Buick Century, Regal 1997-2001 Buick Regal (Export China) 1997-2001 Chevrolet Trans Sport (Export China), Venture 2000-2001 Chevrolet Impala, Monte Carlo 1998-2001 Oldsmobile Intrigue 1997-1998 Pontiac Trans Sport 1997-2001 Pontiac Grand Prix 1999-2001 Pontiac Montana This bulletin is being revised to update the model information. Please discard Corporate Bulletin Number 01-05-23-006 (Section 05 - Brakes). This bulletin is being issued to revise the fastener requirements for the front and rear brake caliper bracket replacement procedures in the Disc-Brake sub-section of Brakes in the appropriate Service Manual. Please use the following to replace the existing information in the Service Manual. This information has been updated within SI2000. If you are using a paper version of this Service Manual, please mark a reference to this bulletin on the affected page in the Disc-Brake sub-section of the Service Manual. Front Brake Caliper Bracket Replacement (All Above Listed Vehicles) 1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanics wire or equivalent. It is not necessary to disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the front brake pads. 3. Remove the caliper bracket bolts (2). 4. Remove the caliper bracket (1). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-03-10-008A > Feb > 02 > All Technical Service Bulletins for Brake Caliper: > 01-05-23-006A > Jun > 01 > Brake Calipers - Revised Fastener Requirements > Page 8020 Important: To ensure that the proper clamp load will be present when installed, it is imperative that the threads on the caliper bracket bolts, as well as the mounting holes in the knuckle, be cleaned of all debris and inspected before proceeding with installation. 5. Clean and visually inspect threads of the caliper bracket bolts (2) and mounting holes in the knuckle. 6. Apply LOCTITE(R) THREAD LOCKER 272 (GM P/N 12345493) or equivalent to the threads of the brake caliper bracket bolts (2). 7. Install the caliper bracket (1) with the bracket bolts (2). Tighten Tighten the caliper bracket bolts to 180 N.m (133 lb ft). 8. Install the front brake pads. 9. Install the caliper. Rear Brake Caliper Bracket Replacement (See Vehicles Listed Below) ^ 1999-2001 Buick Century, Regal ^ 1999-2001 Buick Regal (Export China) ^ 2000-2001 Chevrolet Impala, Monte Carlo ^ 2000-2001 Chevrolet Trans Sport (Export China) ^ 1998-2001 Oldsmobile Intrigue ^ 1997-2001 Pontiac Grand Prix 1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanics wire or equivalent. It is not necessary to disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the rear brake pads. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-03-10-008A > Feb > 02 > All Technical Service Bulletins for Brake Caliper: > 01-05-23-006A > Jun > 01 > Brake Calipers - Revised Fastener Requirements > Page 8021 3. Remove the caliper bracket bolts (2). 4. Remove the caliper bracket (1). Important: To ensure that the proper clamp load will be present when installed, it is imperative that the threads on the caliper bracket bolts, as well as the mounting holes in the knuckle, be cleaned of all debris and inspected before proceeding with installation. 5. Clean and visually inspect threads of the caliper bracket bolts (2) and mounting holes in the knuckle. 6. Apply LOCTITE(R) THREAD LOCKER 272 (GM P/N 12345493) or equivalent to the threads of the brake caliper bracket bolts (2). 7. Install the caliper bracket (1) with the bracket bolts (2). Tighten Tighten the caliper bracket bolts to 115 N.m (85 lb ft). 8. Install the rear brake pads. 9. Install the caliper. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-03-10-008A > Feb > 02 > All Technical Service Bulletins for Brake Caliper: > 01-05-23-003 > Mar > 01 > Front/Rear Brakes - Revised Tool Requirements Technical Service Bulletin # 01-05-23-003 Date: 010301 Front/Rear Brakes - Revised Tool Requirements File In Section: 05 - Brakes Bulletin No.: 01-05-23-003 Date: March, 2001 SERVICE MANUAL UPDATE Subject: Revised Tool Requirements for Front and Rear Brake Caliper Overhaul Models: 1997-2001 Buick Park Avenue, Regal 1997-2001 Buick Regal (Export China) 2000-2001 Buick LeSabre 1997-2001 Cadillac DeVille, Seville 2000-2001 Cadillac Eldorado 1997-2001 Chevrolet Trans Sport (Export China), Venture 2000-2001 Chevrolet Impala, Lumina, Monte Carlo 1997-2001 Oldsmobile Aurora, Silhouette 1998-2001 Oldsmobile Intrigue 1997-2001 Pontiac Grand Prix, Montana, Trans Sport 2000-2001 Pontiac Bonneville This bulletin is being issued to revise the tool requirements for the front and rear brake caliper overhaul procedures in the Disc-Brake sub-section of Brakes in the appropriate Service Manual. Please use the following to replace the existing information in the Service Manual. This information has been updated within SI2000. If you are using a paper version of this Service Manual, please mark a reference to this bulletin on the affected page in the Disc Brake sub-section of the Service Manual. DISCLAIMER Front Brake Caliper Overhaul Procedure (All Above Listed Vehicles) Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury. Notice: Use clean cloths to pad the interior of the caliper housing during piston removal. Use just enough air to ease the piston out of the bores. If the pistons are blown out, even with the padding provided it may be damaged. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-03-10-008A > Feb > 02 > All Technical Service Bulletins for Brake Caliper: > 01-05-23-003 > Mar > 01 > Front/Rear Brakes - Revised Tool Requirements > Page 8026 1. Remove the front brake caliper from the vehicle. 2. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole. 3. Using a small wooden or plastic tool, remove the caliper piston seal (2) from the seal counterbore in the caliper (1) and discard the boot seal. 4. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore and discard the piston seal. 5. Remove the bleeder valve (5) and cap (6) from the caliper (1). Important: Do not use abrasives to clean the brake caliper piston. 6. Clean the brake caliper piston bore and seal counterbore and the caliper piston with denatured alcohol, or equivalent. 7. Dry the caliper piston bore and counterbore and the piston with non-lubricated, filtered air. 8. Inspect the caliper bore for cracks, scoring, pitting, excessive rust and/or excessive corrosion. 9. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 10. If cracks, scoring, pitting, excessive rust and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 11. Inspect the caliper piston for cracks, scoring and/or damage to the finished surface area. Replace the caliper piston if any of these conditions exist. 12. Lubricate the new piston seal with Delco Supreme 11(R), P/N 12377967 (in Canada use P/N 992668), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 13. Install the lubricated new piston seal into the caliper bore. 14. Install the caliper piston into the caliper bore. Press the piston to the bottom of the bore. 15. Install the new piston dust boot seal over the piston. 16. Use J-35777 to fully seat the caliper piston seal into the counterbore. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-03-10-008A > Feb > 02 > All Technical Service Bulletins for Brake Caliper: > 01-05-23-003 > Mar > 01 > Front/Rear Brakes - Revised Tool Requirements > Page 8027 17. Install the bleeder valve and cap to the caliper and tighten the valve securely. 18. Install the front brake caliper to the vehicle. Rear Brake Caliper Overhaul Procedure (See Vehicles Listed Below) ^ 1999-2001 Buick Regal ^ 1999-2001 Buick Regal (Export China) ^ 2000-2001 Chevrolet Impala, Monte Carlo, Trans Sport (Export China) ^ 1998-2001 Oldsmobile Intrigue ^ 1997-2001 Pontiac Grand Prix Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury. Notice: Use clean cloths to pad the interior of the caliper housing during piston removal. Use just enough air to ease the piston out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. 1. Remove the rear brake caliper from the vehicle. 2. Remove the bleeder valve and cap from the caliper housing. 3. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole. 4. Remove the retaining ring that secures the dust boot to the caliper housing. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-03-10-008A > Feb > 02 > All Technical Service Bulletins for Brake Caliper: > 01-05-23-003 > Mar > 01 > Front/Rear Brakes - Revised Tool Requirements > Page 8028 5. Remove the piston dust boot seal (2) from the seal counterbore in the caliper. Discard the boot seal. 6. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore. Discard the piston seal. Important: Do not use abrasives to clean the brake caliper piston. 7. Clean the brake caliper piston bore and seal counterbore and the caliper piston with denatured alcohol, or equivalent. 8. Dry the caliper piston bore and counterbore and the piston with non-lubricated, filtered air. 9. Inspect the caliper bore for cracks, scoring, pitting, excessive rust and/or excessive corrosion. 10. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 11. If cracks, scoring, pitting, excessive rust and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 12. Inspect the caliper piston for cracks, scoring and/or damage to the chrome plating. Replace the caliper piston if any of these conditions exist. 13. Lubricate the new piston seal (4) with Delco Supreme 11(R), P/N 12377967 (in Canada, use P/N 992668), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Install the lubricated new piston seal (4) into the caliper bore. 15. Install the bottom half of the caliper piston (3) into the caliper bore. 16. Install the new piston dust boot seal (2) over the caliper piston (3). 17. Compress the caliper piston (3) to the bottom of the caliper bore. 18. Fully seat the piston dust boot seal (2) into caliper counterbore. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-03-10-008A > Feb > 02 > All Technical Service Bulletins for Brake Caliper: > 01-05-23-003 > Mar > 01 > Front/Rear Brakes - Revised Tool Requirements > Page 8029 19. Install the retaining ring that secures the dust boot to the caliper housing. 20. Install the bleeder valve and cap to the caliper and tighten the valve securely. 21. Install the rear brake caliper to the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Component Specifications Inflatable Restraint Sensing And Diagnostic Module (SDM) (C2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Component Information > Specifications Inflatable Restraint Sensing and Diagnostic Module: Specifications Inflatable Restraint Sensing and Diagnostic Module Fasteners 10 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Component Information > Diagrams > Inflatable Restraint Sensing and Diagnostic Module (SDM)(C1) Inflatable Restraint Sensing And Diagnostic Module (SDM) (C1) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Component Information > Diagrams > Inflatable Restraint Sensing and Diagnostic Module (SDM)(C1) > Page 8037 Inflatable Restraint Sensing And Diagnostic Module (SDM) (C2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Component Information > Diagrams > Page 8038 Inflatable Restraint Sensing and Diagnostic Module: Service Precautions CAUTION: Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. CAUTION: If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal Injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the Ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Component Information > Diagrams > Page 8039 Inflatable Restraint Sensing and Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE The inflatable restraint Sensing and Diagnostic Module (SDM) performs the following functions in the SIR system: ^ Energy Reserve - The SDM maintains a 23 Volt Loop Reserve (23 VLR) energy supply to provide deployment energy for the air bags. Ignition voltage can provide deployment energy if the 23 Volt Loop Reserves malfunction. ^ Crash Detection Frontal - The SDM monitors vehicle velocity changes in order to detect frontal crashes that are severe enough to warrant deployment. - Side - The SDM monitors vehicle velocity changes along with SIS information in order to detect side impact crashes that are severe enough to warrant deployment. ^ Air Bag Deployment Frontal - During a frontal crash of sufficient force, the SDM will cause enough current to flow through the frontal inflator modules to deploy the frontal air bags. - Side - During a side crash of sufficient force, the SDM will cause enough current to flow through the side impact module to deploy the driver side air bag. ^ Frontal Crash Recording - The SDM records information regarding the SIR system status during a frontal crash. ^ Side Impact System Malfunction Monitoring - The SDM monitors the SIS. The SIS can communicate the status of the side impact air bag system to the SDM. ^ Malfunction Detection - The SDM performs diagnostic monitoring of the SIR system electrical components. Upon detection of a circuit or component malfunction, the SDM will set a DTC. ^ Malfunction Diagnosis - The SDM displays SIR DTCs and system status information through the use of a scan tool. ^ Driver Notification - The SDM notifies the vehicle driver of SIR system malfunctions by controlling the AIR BAG warning lamp in the instrument cluster via Class 2 serial data. The SDM connects to the SIR wiring harness using the following connector(s): ^ The 18-way connector provides power, ground, and all the required interfaces for frontal air bag deployment. ^ The 8-way connector (AJ7) provides all the required interfaces for side impact sensing and side air bag deployment. The SDM receives power whenever the ignition is ON. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) Inflatable Restraint Sensing and Diagnostic Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module (AJ7) CAUTION: Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. CAUTION: If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the passenger front seat. 3. Remove the passenger front carpet retainer, then roll back the carpet. 4. Remove the Connector Position Assurance (CPA) from the inflatable restraint sensing and diagnostic module (SDM) 8-way wiring harness connector. 5. Disconnect the SDM 8-way wiring harness connector from the SDM. 6. Remove the connector position assurance (CPA) from the SDM 18-way wiring harness connector (2). 7. Disconnect the SDM 18-way wiring harness connector from the SDM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 8042 8. Remove the SDM mounting fasteners (3). 9. Remove the SDM (1) from the floor pan (2). INSTALLATION PROCEDURE 1. Install the SDM (1) to the floor pan (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the SDM mounting fasteners (3). Tighten Tighten fasteners to 10 N.m (89 lb in). 3. Install the SDM 18-way wiring harness connector to the SDM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 8043 4. Install the connector position assurance (CPA) to the SDM 18-way wiring harness connector. 5. Install the SDM 8-way wiring harness connector to the SDM. 6. Install the connector position assurance (CPA) to the SDM 8-way wiring harness connector. 7. Install the carpet and the passenger front carpet retainer. 8. Install the passenger front seat. 9. Enable the SIR system. Refer to Enabling the SIR System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 8044 Inflatable Restraint Sensing and Diagnostic Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module (AK5) CAUTION: Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. CAUTION: If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the passenger front seat. 3. Remove the passenger front carpet retainer, then roll back the carpet. 4. Remove the Connector Position Assurance (CPA) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector. 5. Disconnect the SDM wiring harness connector from the SDM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 8045 6. Remove the SDM mounting fasteners (3). 7. Remove the SDM (1) from the floor pan (2). INSTALLATION PROCEDURE 1. Install the SDM (1) to the floor pan (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the SDM mounting fasteners (3). Tighten Tighten fasteners to 10 N.m (89 lb in). 3. Install the SDM wiring harness connector to the SDM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 8046 4. Install the connector position assurance (CPA) to the SDM wiring harness connector. 5. Install the carpet and the passenger front carpet retainer. 6. Install the passenger front seat. 7. Enable the SIR system. Refer to Enabling the SIR System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Component Information > Locations Transmission Position Switch/Sensor: Locations Inside the automatic transaxle Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Component Information > Locations > Page 8049 Park Neutral Position (PNP) Switch C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Component Information > Service and Repair > Ignition Switch Lock Cylinder - Dash Mounted Ignition Switch Lock Cylinder: Service and Repair Ignition Switch Lock Cylinder - Dash Mounted IGNITION SWITCH LOCK CYLINDER REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the body control module (BCM) theft deterrent relearn procedure whenever you replace the ignition switch lock cylinder. See: Computers and Control Systems/Body Control Module/Service and Repair/Procedures/Body Control Module (BCM) Programming/RPO Configuration 1. Disconnect the negative battery cable. 2. Remove the instrument panel (I/P) cluster trim plate. 3. Insert the key and turn the ignition lock cylinder to the ON/RUN position. 4. Using a small curved tool or an L-shaped hex wrench, depress and hold the detent on the ignition lock cylinder. Access the detent by placing the tool through the I/P opening to the right of the ignition switch. If you cannot locate the detent with the tool, lower the ignition switch away from the I/P. Refer to Ignition Switch Replacement. 5. Using the key as an aid, pull to remove the lock cylinder from the switch. 6. Remove the key from the lock cylinder. 7. If the cylinder does not rotate or is seized, follow the procedure in the ignition switch replacement. Refer to Ignition Switch Replacement. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Component Information > Service and Repair > Ignition Switch Lock Cylinder - Dash Mounted > Page 8053 1. Code the ignition lock cylinder, if necessary. Refer to Key and Lock Cylinder Coding. 2. Insert the key and turn the lock cylinder to the ON/RUN position. 3. Position the lock cylinder to the ignition switch. Press the cylinder into place. If you turned the key slightly while removing the lock cylinder, you may have to align the white colored ignition switch rotor (1) with the lock cylinder (2). You can rotate the ignition switch rotor (1) with your finger. 4. Turn the key to the OFF position and remove the key. 5. Install the I/P cluster trim plate. 6. Connect the negative battery cable. 7. If you installed a new lock cylinder, perform the BCM theft deterrent relearn procedure. See: Computers and Control Systems/Body Control Module/Service and Repair/Procedures/Body Control Module (BCM) Programming/RPO Configuration Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Component Information > Service and Repair > Ignition Switch Lock Cylinder - Dash Mounted > Page 8054 Ignition Switch Lock Cylinder: Service and Repair Programming/Learn Procedures Programming Replacement Lock Cylinder, BCM or PCM IMPORTANT: Reprogram the body control module (BCM) with the proper RPO configurations before you perform the learn procedures. When you replace the BCM, the module will learn Passlock Sensor Data Code immediately. However, the existing PCM must learn the new fuel continue password. When you replace a PCM, after programming, these modules will learn the incoming fuel continue password immediately upon receipt of a password message. Once a password message is received, and a password is learned, perform the learn procedure again if you want to change this password. A PCM which was previously installed in another vehicle will have learned the other vehicle's fuel continue password, and will require a learn procedure after programming in order to learn the current vehicle's password. 10 Minute Re-Learn Procedure Use this procedure after replacing any of the following components: 1. Lock Cylinders/Passlock Sensors 2. BCM 3. PCM Tech 2 Programming Procedure Use the following procedures in order to program the BCM with the Tech 2 equipment. 1. Connect the Tech 2 Diagnostic tool. 2. Select Request Information under Service Programming. 3. Disconnect the Tech 2 from the vehicle and connect it to a Techline Terminal. 4. On the Techline Terminal, select Theft Module Re-Learn under Service Programming. 5. Disconnect the Tech 2 from the Techline Terminal and connect the Tech 2 to the vehicle. 6. Turn ON the ignition, with the engine OFF. 7. Select VTD Re-Learn under Service Programming. 8. At this point you may disconnect the Tech 2, the Tech 2 is no longer required. 9. Observe the Security telltale, after approximately 10 minutes the telltale will turn OFF. The vehicle is now ready to relearn the Passlock Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. 10. Turn OFF the ignition, and wait 5 seconds. 11. Start the engine. (The vehicle has now learned keys). 12. Using a scan tool, clear any DTCs. 30 Minute Re-Learn Procedure Use this procedure after replacing lock cylinders, Passlock Module/BCM or the PCM (if necessary - see note above). 1. Turn ON the ignition, with the engine OFF. 2. Attempt to start the engine, then release the key to ON (The vehicle will not start). 3. Observe the Security telltale, after approximately 10 minutes the telltale will turn OFF. 4. Turn OFF the ignition, and wait 5 seconds. 5. Repeat steps 1-4 two more times, for a total of 3 cycles and 30 minutes. The vehicle is now ready to relearn the Passlock Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. IMPORTANT: The vehicle learns the Passlock Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. You must turn the ignition OFF before attempting to start the vehicle. 6. Start the engine. (The vehicle has now learned the Passlock Sensor Data Code and/or password.) 7. Using a scan tool, clear any DTCs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 00-05-23-006 > Sep > 00 > Rear Disc Brakes Groan/Squeal Noises Brake Pad: Customer Interest Rear Disc Brakes - Groan/Squeal Noises File In Section: 05 - Brakes Bulletin No.: 00-05-23-006 Date: September, 2000 Subject: Rear Disc Brake Groan/Squeal (Install New Rear Brake Pads) Models: 2000-2001 Chevrolet Impala, Monte Carlo Built Prior to VIN Breakpoint 19117621 Condition Some customers may comment on an audible groan/squeal type noise coming from the rear of the vehicle during a light brake apply. This condition is most likely to occur after the vehicle has sat overnight and may be apparent in either forward and/or reverse gears. Cause This noise may be generated at the rear brake pad/rotor interface during a brake application. The noise is then transmitted into the vehicle's underbody through the rear suspension components. Correction Replace the existing rear disc brake pads with those found in service kit, P/N 18023377, following the service procedure in the Disc Brake sub-section of the Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 00-05-23-006 > Sep > 00 > Rear Disc Brakes - Groan/Squeal Noises Brake Pad: All Technical Service Bulletins Rear Disc Brakes - Groan/Squeal Noises File In Section: 05 - Brakes Bulletin No.: 00-05-23-006 Date: September, 2000 Subject: Rear Disc Brake Groan/Squeal (Install New Rear Brake Pads) Models: 2000-2001 Chevrolet Impala, Monte Carlo Built Prior to VIN Breakpoint 19117621 Condition Some customers may comment on an audible groan/squeal type noise coming from the rear of the vehicle during a light brake apply. This condition is most likely to occur after the vehicle has sat overnight and may be apparent in either forward and/or reverse gears. Cause This noise may be generated at the rear brake pad/rotor interface during a brake application. The noise is then transmitted into the vehicle's underbody through the rear suspension components. Correction Replace the existing rear disc brake pads with those found in service kit, P/N 18023377, following the service procedure in the Disc Brake sub-section of the Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Page 8068 Brake Pad: Specifications Replace the disc brake pads whenever the thickness of any brake pad is worn to within 0.76 mm (0.030 inch) of the pad. In the case of riveted brake pads, replace the pads when the pad wears to within 0.76 mm (0.030 inch) of any rivet head. Replace disc brake pads in axle sets (front / rear) at the same time. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement - Front Brake Pad: Service and Repair Brake Pads Replacement - Front Removal Procedure GM replacement brake lining material (or equivalent) is recommended for all GM vehicles in order to maintain the balance between front and rear brake performance. GM replacement brake parts have been carefully selected in order to provide the proper brake balance for purposes of both stopping distance and control over the full range of operation conditions. Installation of the front or rear brake lining material that has performance different than that of the GM replacement parts recommended for this vehicle may change the intended brake balance of this vehicle. 1. Remove one-third of the brake fluid from the master cylinder. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Mark the relationship of the wheel to the hub. 4. Remove the tire and the wheel. Refer to Tire and Wheel Removal and Installation. Install two wheel nuts in order to retain the rotor. 5. Push the piston onto the caliper bore in order to provide clearance between the pads and the rotor. Complete the following steps: 5.1. Install a large C-clamp (2) over the top of the caliper housing (1) and against the back of the outboard pad. 5.2. Slowly tighten the C-clamp (2) until the piston pushes into the caliper bore enough to slide the caliper (1) off the rotor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement - Front > Page 8071 6. Remove the lower caliper bolt (1). Notice: Use care to avoid damaging pin boot when rotating caliper 7. Rotate the caliper upward in order to access the pads. 8. Remove the pads from the caliper bracket. 9. Remove the two retainers from the caliper bracket. 10. Inspect the following parts for cuts, tears, or deterioration. Replace any damaged parts: ^ The bolt boots. Refer to Brake Caliper Bracket Replacement (Front). ^ The piston boot. Refer to Brake Caliper Overhaul (Front). ^ The bolt boots in the caliper bracket. Refer to Brake Caliper Bracket Replacement (Front). 11. Inspect the caliper bolts for corrosion or damage. If corrosion is found, use new parts, including bushings, when installing the caliper. Do not attempt to polish away corrosion. Installation Procedure Important: Before installing new brake pads, wipe the outside surface of the caliper boot clean. Use denatured alcohol. 1. Bottom the piston into the caliper bore. If installing new brake pads, use a C-clamp in order to clamp the piston at the same time. Use a metal plate or wooden block across the face of the piston. Do not damage the piston or the caliper boot. Important: Lift the inner edge caliper boot next to the piston. Press out any trapped air. The boot must lay flat below the level of the piston face. 2. Install the two retainers to the caliper bracket. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement - Front > Page 8072 Notice: Inner and outer brake pads must be new or parallel. Parking brake adjustment is not valid with tapered pads, and may cause caliper/parking brake binding. This will result in overheating and possible damage of the brake linings, rotor, and/or caliper. Important: The wear sensor is on the outside pad. The sensor is positioned at the leading edge (upward) of the pad during forward wheel rotation. 3. Install the pads to the caliper anchor bracket. Notice: Use care to avoid damaging pin boot when rotating caliper. 4. Swing the caliper down onto the pads. 5. Lubricate the bolt and the bolt boot. Use silicone grease. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the lower caliper bolt. ^ Tighten the caliper bolts to 85 Nm (63 ft. lbs.). 7. Remove the wheel nuts securing the rotor to the hub. 8. Install the tires and the wheels. Refer to Tire and Wheel Removal and Installation. Align the previous marks on the wheel and the hub. 9. Lower the vehicle. 10. Fill the master cylinder to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling. 11. Apply the brake pedal approximately three times in order to seat the pads. 12. Burnish the pads and the rotors. Refer to Burnishing Pads and Rotors. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement - Front > Page 8073 Brake Pad: Service and Repair Brake Pads Replacement - Rear Removal Procedure Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury. 1. Remove one-third of the brake fluid from the master cylinder. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Mark the relationship of the wheel to the axle flange. 4. Remove the tire and the wheel. Refer to Tire and Wheel Removal and Installation. Install two wheel nuts to retain the rotor. 5. Compress the caliper piston enough for clearance. Use a C-clamp (3). 6. Remove the upper caliper bolt (2). 7. Pivot the caliper body down in order to access the pads. Do not remove the caliper body. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement - Front > Page 8074 8. Remove the brake pads (9,10) from the caliper bracket. 9. Remove the two pad clips (11) from the caliper bracket. 10. Inspect the caliper bracket boots for the following conditions: ^ Cuts ^ Tears ^ Deterioration Replace the bracket boots if damage exists. Refer to or Brake Caliper Bracket Replacement (Rear). 11. Inspect the piston boot (8) for the following conditions: ^ Cuts ^ Tears ^ Deterioration Replace the piston boot if damage exists. Refer to Brake Caliper Overhaul (Rear). 12. Inspect the caliper bolts for corrosion or damage. If corrosion exists, use new components (including bushings) when installing the caliper. Do not attempt to polish away the corrosion. Installation Procedure Important: Before installing new brake pads, wipe the outside surface of the caliper boot clean. Use denatured alcohol. 1. Bottom the piston (7) into the caliper bore (2). Use a C-clamp when installing new brake pads in order to clamp the piston at the same time. Use a metal plate or wooden block across the face of the piston. Do not damage the piston or the caliper boot. Important: Lift the inner edge caliper boot (4) next to the piston (7). Press out any trapped air. The boot must lay flat below the level of the piston face. 2. Install the two retainers (11) to the caliper bracket (12). Important: The wear sensor is on the outside pad. The sensor is positioned at the trailing edge (downward) of the pad during forward wheel rotation. 3. Install the pads (9 and 10) to the caliper bracket (12). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement - Front > Page 8075 Notice: Use care to avoid damaging pin boot when rotating caliper. 4. Swing the caliper upward in position around the pads. 5. Lubricate the bolt and the bolt boot. Use silicone grease. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the upper caliper bolt. ^ Tighten the caliper bolt to 44 Nm (32 ft. lbs.). 7. Remove the wheel nuts securing the rotor to the hub and bearing. 8. Install the tires and the wheels. Refer to Tire and Wheel Removal and Installation. Align the previous marks on the wheel, hub and bearing. 9. Lower the vehicle. 10. Fill the master cylinder to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling. 11. Apply the brake pedal approximately three times in order to seat the pads. 12. Burnish the pads and the rotors. Refer to Burnishing Pads and Rotors. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement - Front > Page 8076 Brake Pad: Service and Repair Burnishing Pads and Rotors ^ Burnish the new braking surface after the brake pads have been replaced. ^ Burnish the new braking surface after the rotors have been refinished or replaced. ^ Burnish the new braking surface by making 20 stops from 48 km/H (30 mph). ^ Use medium to firm pressure on the brake pedal. ^ Allow adequate cooling between stops. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest: > 00-05-23-006 > Sep > 00 > Rear Disc Brakes Groan/Squeal Noises Brake Rotor/Disc: Customer Interest Rear Disc Brakes - Groan/Squeal Noises File In Section: 05 - Brakes Bulletin No.: 00-05-23-006 Date: September, 2000 Subject: Rear Disc Brake Groan/Squeal (Install New Rear Brake Pads) Models: 2000-2001 Chevrolet Impala, Monte Carlo Built Prior to VIN Breakpoint 19117621 Condition Some customers may comment on an audible groan/squeal type noise coming from the rear of the vehicle during a light brake apply. This condition is most likely to occur after the vehicle has sat overnight and may be apparent in either forward and/or reverse gears. Cause This noise may be generated at the rear brake pad/rotor interface during a brake application. The noise is then transmitted into the vehicle's underbody through the rear suspension components. Correction Replace the existing rear disc brake pads with those found in service kit, P/N 18023377, following the service procedure in the Disc Brake sub-section of the Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8090 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8091 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8092 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8093 WARRANTY INFORMATION Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8094 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8095 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8096 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8097 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8098 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8099 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8100 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8101 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8102 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8103 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 01-05-23-001B > Jan > 08 > Brakes - Rotor Lateral Runout Correction Information Brake Rotor/Disc: All Technical Service Bulletins Brakes - Rotor Lateral Runout Correction Information Bulletin No.: 01-05-23-001B Date: January 31, 2008 INFORMATION Subject: Brake Align(R) System for Brake Rotor Lateral Runout Correction Models: 2008 and Prior Passenger Cars Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 01-05-23-001A (Section 05 - Brakes). This bulletin is being issued to update General Motors position on correcting brake rotor lateral runout (Refer to Corporate Bulletin Number 00-05-22-002B for additional brake rotor service procedures). Certain conditions may apply to individual vehicles regarding specific repairs. Refer to those specific repairs in applicable service bulletins. Make sure other possible sources of brake pulsation, such as ABS pedal feedback, have been addressed before checking rotor runout. Anytime a new or refinished rotor is installed on a vehicle, the rotor must have .050 mm (.002 in) or less of lateral runout. This specification is important to prevent comebacks for brake pulsation. Until now, the only acceptable methods to correct brake rotor runout were to index or replace the rotor or to refinish the rotor using an on-vehicle brake lathe. GM has approved a new technology for the correction of lateral runout on new or refinished rotors. This new method is called Brake align(R)*. It will allow the technician to meet the .050 mm (.002 in) or less requirement for lateral runout by installing a specially selected, tapered correction plate between the rotor and the hub. The Brake Align(R) Correction system does NOT require the use of an on-vehicle brake lathe to correct for lateral runout. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. The Brake Align(R) Starter Kit will include an ample supply of Correction Plates, in various correction sizes, that will cover most current GM passenger car applications. It will also include a Brake Align(R) tool kit containing a dial indicator and retaining washers along with other useful tools. Service Procedure Follow all the procedures referred to in Corporate Bulletin Number 00-05-22-002B. Dealers who have purchased the Brake Align(R) Starter Kit may use the following simplified runout correction procedure: The existing rotors must first be machined on an approved, well-maintained bench lathe to guarantee smooth, flat, and parallel surfaces. Should the rotors require replacement, please note that it is not necessary to machine new rotors. Make sure all the mating surfaces of the rotor and the hub are clean, using the J 42450-A wheel Hub Cleaning Kit. Mount the new or refinished rotor onto the vehicle hub using the retaining washers provided in the kit. Do not reinstall the caliper or wheel at this time. Tighten all the wheel nuts to the proper specification, using J 39544 Torque Socket or the equivalent. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor friction surface approximately 12.7 mm (1/2 in) from the rotors outer edge. Rotate the rotor and observe the total lateral runout. Index the rotor on the hub to achieve the lowest amount of lateral runout. This will require removal and reassembly of the rotor until the lowest total lateral runout reading is obtained. If this reading is .050 mm (.002 in) or less, the assembled rotor is within specification. The brake system may be reassembled. If total lateral runout is greater than .050 mm (.002 in), proceed with determining the correct Brake Align(R) Correction as follows: Rotate the rotor to locate the lowest dial indicator reading and set the dial to zero. Rotate the rotor to determine and locate the highest amount of lateral runout. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 01-05-23-001B > Jan > 08 > Brakes - Rotor Lateral Runout Correction Information > Page 8108 Note the AMOUNT and LOCATION of the "high spot" on the rotor and mark the closest wheel stud relative to this location. Remove the rotor. Select the appropriate Brake Align(R) Runout Correction Plate for this vehicle using the Application Chart. Make sure the selection corrects the amount of runout that was diagnosed. Never attempt to stack two or more Correction Plates together on one hub. Never attempt to re-use a previously installed Correction Plate. Following the Brake Align(R) procedures and diagram, install the Correction Plate onto the vehicle between the hub and the rotor. The V-notch in the Correction Plate is to be installed and aligned with the noted location of the "high spot" on the vehicle hub and marked wheel stud. Install the rotor onto the vehicle with the Correction Plate placed between the hub and the rotor. Be sure to install the rotor onto the hub in the same location as identified in Step 7. The rotor should then be secured onto the hub and tightened to the proper specification. The rotor should be dial indicated once more to assure that the rotor is now within specification. The brake system is now ready for the remaining service and assembly. Once the caliper has been installed, check to ensure that the rotor rotates freely. Parts Information Brake Align(R) Runout Correction Plates are available through the suppliers shown. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 01-05-23-001B > Jan > 08 > Brakes - Rotor Lateral Runout Correction Information > Page 8109 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 01-05-23-001B > Jan > 08 > Brakes - Rotor Lateral Runout Correction Information > Page 8110 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 01-05-23-001B > Jan > 08 > Brakes - Rotor Lateral Runout Correction Information > Page 8111 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 01-05-23-001B > Jan > 08 > Brakes - Rotor Lateral Runout Correction Information > Page 8112 Brake Align Order Form Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 05-05-23-004 > Jun > 05 > Brakes - Revised Brake Rotor Specifications Brake Rotor/Disc: All Technical Service Bulletins Brakes - Revised Brake Rotor Specifications Bulletin No.: 05-05-23-004 Date: June 17, 2005 SERVICE MANUAL UPDATE Subject: Revised Brake Rotor Specifications Models: 1997-2000 Buick Century, Regal 2000 Chevrolet Impala, Monte Carlo 1998-2000 Oldsmobile Intrigue 1997-2000 Pontiac Grand Prix This bulletin is being issued to revise the front and rear brake rotor minimum allowable thickness after refinish specification in the Disc Brakes sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-23-006 > Sep > 00 > Rear Disc Brakes - Groan/Squeal Noises Brake Rotor/Disc: All Technical Service Bulletins Rear Disc Brakes - Groan/Squeal Noises File In Section: 05 - Brakes Bulletin No.: 00-05-23-006 Date: September, 2000 Subject: Rear Disc Brake Groan/Squeal (Install New Rear Brake Pads) Models: 2000-2001 Chevrolet Impala, Monte Carlo Built Prior to VIN Breakpoint 19117621 Condition Some customers may comment on an audible groan/squeal type noise coming from the rear of the vehicle during a light brake apply. This condition is most likely to occur after the vehicle has sat overnight and may be apparent in either forward and/or reverse gears. Cause This noise may be generated at the rear brake pad/rotor interface during a brake application. The noise is then transmitted into the vehicle's underbody through the rear suspension components. Correction Replace the existing rear disc brake pads with those found in service kit, P/N 18023377, following the service procedure in the Disc Brake sub-section of the Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8126 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8127 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8128 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8129 WARRANTY INFORMATION Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8130 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8131 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8132 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8133 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8134 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8135 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8136 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8137 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8138 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 8139 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 01-05-23-001B > Jan > 08 > Brakes - Rotor Lateral Runout Correction Information Brake Rotor/Disc: All Technical Service Bulletins Brakes - Rotor Lateral Runout Correction Information Bulletin No.: 01-05-23-001B Date: January 31, 2008 INFORMATION Subject: Brake Align(R) System for Brake Rotor Lateral Runout Correction Models: 2008 and Prior Passenger Cars Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 01-05-23-001A (Section 05 - Brakes). This bulletin is being issued to update General Motors position on correcting brake rotor lateral runout (Refer to Corporate Bulletin Number 00-05-22-002B for additional brake rotor service procedures). Certain conditions may apply to individual vehicles regarding specific repairs. Refer to those specific repairs in applicable service bulletins. Make sure other possible sources of brake pulsation, such as ABS pedal feedback, have been addressed before checking rotor runout. Anytime a new or refinished rotor is installed on a vehicle, the rotor must have .050 mm (.002 in) or less of lateral runout. This specification is important to prevent comebacks for brake pulsation. Until now, the only acceptable methods to correct brake rotor runout were to index or replace the rotor or to refinish the rotor using an on-vehicle brake lathe. GM has approved a new technology for the correction of lateral runout on new or refinished rotors. This new method is called Brake align(R)*. It will allow the technician to meet the .050 mm (.002 in) or less requirement for lateral runout by installing a specially selected, tapered correction plate between the rotor and the hub. The Brake Align(R) Correction system does NOT require the use of an on-vehicle brake lathe to correct for lateral runout. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. The Brake Align(R) Starter Kit will include an ample supply of Correction Plates, in various correction sizes, that will cover most current GM passenger car applications. It will also include a Brake Align(R) tool kit containing a dial indicator and retaining washers along with other useful tools. Service Procedure Follow all the procedures referred to in Corporate Bulletin Number 00-05-22-002B. Dealers who have purchased the Brake Align(R) Starter Kit may use the following simplified runout correction procedure: The existing rotors must first be machined on an approved, well-maintained bench lathe to guarantee smooth, flat, and parallel surfaces. Should the rotors require replacement, please note that it is not necessary to machine new rotors. Make sure all the mating surfaces of the rotor and the hub are clean, using the J 42450-A wheel Hub Cleaning Kit. Mount the new or refinished rotor onto the vehicle hub using the retaining washers provided in the kit. Do not reinstall the caliper or wheel at this time. Tighten all the wheel nuts to the proper specification, using J 39544 Torque Socket or the equivalent. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor friction surface approximately 12.7 mm (1/2 in) from the rotors outer edge. Rotate the rotor and observe the total lateral runout. Index the rotor on the hub to achieve the lowest amount of lateral runout. This will require removal and reassembly of the rotor until the lowest total lateral runout reading is obtained. If this reading is .050 mm (.002 in) or less, the assembled rotor is within specification. The brake system may be reassembled. If total lateral runout is greater than .050 mm (.002 in), proceed with determining the correct Brake Align(R) Correction as follows: Rotate the rotor to locate the lowest dial indicator reading and set the dial to zero. Rotate the rotor to determine and locate the highest amount of lateral runout. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 01-05-23-001B > Jan > 08 > Brakes - Rotor Lateral Runout Correction Information > Page 8144 Note the AMOUNT and LOCATION of the "high spot" on the rotor and mark the closest wheel stud relative to this location. Remove the rotor. Select the appropriate Brake Align(R) Runout Correction Plate for this vehicle using the Application Chart. Make sure the selection corrects the amount of runout that was diagnosed. Never attempt to stack two or more Correction Plates together on one hub. Never attempt to re-use a previously installed Correction Plate. Following the Brake Align(R) procedures and diagram, install the Correction Plate onto the vehicle between the hub and the rotor. The V-notch in the Correction Plate is to be installed and aligned with the noted location of the "high spot" on the vehicle hub and marked wheel stud. Install the rotor onto the vehicle with the Correction Plate placed between the hub and the rotor. Be sure to install the rotor onto the hub in the same location as identified in Step 7. The rotor should then be secured onto the hub and tightened to the proper specification. The rotor should be dial indicated once more to assure that the rotor is now within specification. The brake system is now ready for the remaining service and assembly. Once the caliper has been installed, check to ensure that the rotor rotates freely. Parts Information Brake Align(R) Runout Correction Plates are available through the suppliers shown. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 01-05-23-001B > Jan > 08 > Brakes - Rotor Lateral Runout Correction Information > Page 8145 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 01-05-23-001B > Jan > 08 > Brakes - Rotor Lateral Runout Correction Information > Page 8146 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 01-05-23-001B > Jan > 08 > Brakes - Rotor Lateral Runout Correction Information > Page 8147 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 01-05-23-001B > Jan > 08 > Brakes - Rotor Lateral Runout Correction Information > Page 8148 Brake Align Order Form Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 05-05-23-004 > Jun > 05 > Brakes - Revised Brake Rotor Specifications Brake Rotor/Disc: All Technical Service Bulletins Brakes - Revised Brake Rotor Specifications Bulletin No.: 05-05-23-004 Date: June 17, 2005 SERVICE MANUAL UPDATE Subject: Revised Brake Rotor Specifications Models: 1997-2000 Buick Century, Regal 2000 Chevrolet Impala, Monte Carlo 1998-2000 Oldsmobile Intrigue 1997-2000 Pontiac Grand Prix This bulletin is being issued to revise the front and rear brake rotor minimum allowable thickness after refinish specification in the Disc Brakes sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 8153 Brake Rotor/Disc: Specifications NOTE: The content of this article/image reflects the changes called out by TSB: 05-05-23-004. Front Important: All brake rotors have a discard dimension cast into them. Replace any rotor that does not meet this specification. After refinishing the rotor, replace any rotor that does not meet the maximum or minimum thickness after refinish specifications. Maximum Lateral Runout 0.003 in Thickness Variation 0.0005 in Maximum Scoring 0.060 in Rotor Discard Thickness 1.21 in Minimum Rotor Thickness 1.22 in New Rotor Thickness 1.27 in Rear Rotor Discard Thickness 0.35 in Minimum Rotor Thickness 0.39 in New Rotor Thickness 0.43 in Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement Brake Rotor/Disc: Service and Repair Brake Rotor Replacement Brake Rotor Replacement (Rear) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and the wheel. Refer to Tire and Wheel Removal and Installation. 3. Remove the caliper bracket. Refer to Brake Caliper Replacement (Rear). 4. Remove the brake rotor. 5. Clean the metal contact surfaces between the brake rotor and the hub bearing flange. Installation Procedure 1. Install the brake rotor. 2. Install the caliper bracket. Refer to Brake Caliper Replacement (Rear). 3. Install the tire and the wheel. Refer to Tire and Wheel Removal and Installation. 4. Lower the vehicle. Brake Rotor Replacement-Front Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and the wheel. Refer to Tire and Wheel Removal and Installation. 3. Remove the caliper bracket. Refer to Brake Caliper Replacement (Front). 4. Remove the brake rotor. 5. Clean the metal contact surfaces between the brake rotor and the hub bearing flange. Installation Procedure 1. Install the brake rotor. 2. Install the caliper bracket. Refer to Brake Caliper Replacement (Front). 3. Install the tire and the wheel. Refer to Tire and Wheel Removal and Installation. 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 8156 Brake Rotor/Disc: Service and Repair Burnishing Pads and Rotors ^ Burnish the new braking surface after the brake pads have been replaced. ^ Burnish the new braking surface after the rotors have been refinished or replaced. ^ Burnish the new braking surface by making 20 stops from 48 km/H (30 mph). ^ Use medium to firm pressure on the brake pedal. ^ Allow adequate cooling between stops. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 8157 Brake Rotor/Disc: Service and Repair Refinishing Rotors Important: DO NOT refinish the brake rotors in order to correct any of the following comments: ^ Brake noise, such as a growl or such as a squeal ^ Premature brake lining wear ^ Superficial corrosion of the rotor braking surface ^ Rotor discoloration Refinish the brake rotors ONLY when one or more of the following conditions exist: ^ Severe scoring of the rotor braking surface (groove depth in excess of specification ^ Brake pulsation that is caused by the following conditions: Lateral runout in excess of specification - Brake rotor thickness variation in excess of specification - Corrosion or pitting that is deeper than the rotor braking surface ^ Tools Required J 42450-A Hub Cleaning Kit - J 41013 Rotor Resurfacing Kit Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange with the J 42450 hub cleaning kit. Failure to do this may result in increased lateral runout of the rotor and brake pulsation. 1. Use the J 42450-A in order to clean the wheel bearing and the wheel bearing hub. 2. Use a micrometer in order to measure the thinnest point of the brake rotor. If the thinnest point of the brake rotor exceeds the brake rotor minimum thickness, do NOT refinish the brake rotor. Replace the brake rotor. 3. Use the J 41013 or an equivalent tool in order to THOROUGHLY clean the rust from the brake rotor flange. 4. Refinish the brake rotor. Refer to the brake lathe manufacturer's operating instructions. Important: Failure to obtain the best possible surface finish may cause poor braking. 5. After machining the rotor, use 120-grit aluminum oxide sandpaper and, if available, a non-directional rotor finisher in order to create a non-directional braking surface. 6. Clean the braking surfaces with GM P/N 12377981, or with an equivalent brake parts cleaner. Notice: Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. To avoid expensive brake repairs, evenly tighten the wheel nuts in the proper torque specification. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure Brake Bleeding: Service and Repair Automated Bleed Procedure Important: In most circumstances a base brake bleed is all that is required for most component replacements (such as wheel cylinders, calipers, brake tubes, and master cylinder), except for BPMV replacement. The following automated ABS bleed procedure is required when one of the following actions occur: ^ Manual bleeding at the wheels does not achieve the desired pedal height or feel. ^ BPMV (Brake Pressure Modulator Valve) replacement ^ Extreme loss of brake fluid has occurred. ^ Air ingestion is suspected. If none of the above conditions apply, use standard bleed procedures. Refer to Hydraulic Brake System Bleeding. The auto bleed procedure is used on DBC 7 equipped vehicles. This procedure uses a scan tool to cycle the system solenoid valves and run the pump in order to purge the air from the secondary circuits. These secondary circuits are normally closed off, and are only opened during system initialization at vehicle start up, and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped inside the BPMV to flow out toward the wheel cylinders or calipers where the air can be purged out of the system. Automated Bleed Procedure ^ Tools Required A scan tool - A 35 psi pressure bleeder with the proper master cylinder adapter - Delco Supreme 11 or equivalent Dot 3 brake fluid from a clean, sealed container - A hoist - An unbreakable plastic bleeder bottle equipped with a hose (in order to recover fluid at the wheels) - An assistant, if needed - Suitable safety attire, including safety glasses Preliminary Inspection 1. Inspect the battery for full charge, repair the battery and charging system as necessary. Refer to Battery Charging. 2. Connect a scan tool to the Data Link Connector (DLC) and select current and history DTCs. Repair any DTCs prior to performing the ABS bleed procedure. 3. Inspect for visual damage and leaks. Repair as needed. Preliminary Setup 1. Raise and support the vehicle on a suitable support. Refer to Vehicle Lifting. 2. Turn the ignition switch to the OFF position. 3. Remove all four tires, if necessary. 4. Connect the pressure bleeding tool according to the manufacturer's instructions. 5. Turn the ignition switch to RUN position, with the engine off. 6. Connect the scan tool and establish communications with the ABS system. 7. Pressurize the bleeding tool to 30 to 35 psi. Performing the Automated Bleed Procedure Notice: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. 1. With the pressure bleeding tool at 30 to 35 psi, and all bleeder screws in closed position, select Automated Bleed Procedure on the scan tool and follow the instructions. 2. The first part of the automated bleed procedure will cycle the pump and front release valves for 1 minute. After the cycling has stopped the scan tool will enter a "cool down" mode and display a 3 minute timer. The auto bleed will not continue until this timer expired, and cannot be overridden. 3. During the next step, the scan tool will request the technician to open one of the bleeder screws. The scan tool will then cycle the respective release valve and pump motor for 1 minute. 4. The scan tool will repeat step 3 for the remaining bleeder screws. 5. With the bleeder tool still attached to the vehicle and maintaining 35 psi, the scan tool will instruct the technician to independently open each bleeder screw for approximately 20 seconds. This should allow any remaining air to be purged from the brake lines. 6. When the automated bleed procedure is completed, the scan tool will display the appropriate message. 7. Remove pressure from the pressure bleeding tool, and then disconnect the tool from the vehicle. 8. Depress the brake pedal in order to gauge the pedal height and feel. Repeat step 1 through step 8 until the pedal height and feel is acceptable. 9. Remove the scan tool from the DLC connector. 10. Install the tire and wheels assemblies, if removed. 11. Lower the vehicle. 12. Inspect the brake fluid level in master cylinder. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 8168 13. Road test the vehicle in order to ensure that the brake pedal remains high and firm. If vehicle is equipped with TCS, the scan tool will cycle both the ABS and TCS solenoids valves. This bleed procedure is the same as the procedure above. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 8169 Brake Bleeding: Service and Repair Manual and Pressure Bleeding Procedures Caution: Do not move the vehicle until a firm brake pedal is obtained. Air in the brake system can cause loss of brakes with possible personal injury. Caution: Use only SUPREME II or equivalent DOT 3 brake fluid from a clean, sealed container. Do not use fluid from an open container that may be contaminated with water. Improper or contaminated fluid will result in damage to components or loss of braking, with possible personal injury. Caution: Do not overfill the brake fluid reservoir. Overfilling the brake fluid reservoir may cause the brake fluid to overflow onto the engine exhaust components during brake system service. The brake fluid is flammable and may cause a fire and personal injury if the brake fluid contacts the engine exhaust system components. Notice: If any brake component is repaired or replaced such that air is allowed to enter the brake system, the entire bleeding procedure must be followed. Notice: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring, cables, or electric connectors. Brake fluid will damage the paint and the electrical connections. If any fluid is spilled on the vehicle, flush the area to lessen the damage. Notice: Prior to bleeding the brakes, the front and rear displacement cylinder pistons must be returned to the topmost position, The preferred method uses a Scan Tool to perform the rehorning procedure. If a Scan Tool is not available, the second procedure may be used, but it is extremely important that the procedure be followed exactly as outlined. A bleeding operation is necessary in order to remove air when air is introduced into the hydraulic brake system. Bleed the hydraulic system at all four brakes if air has been introduced through a low fluid level or by disconnecting brake pipes at the master cylinder. If a brake hose or brake pipe is disconnected at one wheel, bleed only that one wheel caliper. If brake pipes or hoses are disconnected at any fitting located between the master cylinder and the brakes, then only bleed the brake system served by the disconnected pipe or hose. With Scan Tool (Preferred Method) Refer to Automated Bleed Procedure. Without Scan Tool Notice: This method can only be used if the amber ABS warning indicator is not illuminated and no DTCs are present. Important: Do not place your foot on the brake pedal through this entire procedure unless specifically directed to do so. 1. Remove foot from the brake pedal. 2. Start the engine. Allow the engine to run for at least ten seconds while observing the amber ABS warning indicator. 3. If the amber ABS warning indicator turns on and stays on after ten seconds, stop the bleeding procedure. Use a Scan Tool in order to diagnose the ABS malfunction. 4. If the amber ABS warning indicator turns on for approximately three seconds, then turns off and stays off, turn the ignition off. 5. Repeat the previous four steps one more time. 6. Bleed the entire brake system. Pressure Bleeding ^ Tools Required J 29532 Diaphragm Type Brake Bleeder Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 8170 - J 35589 Compact Brake Bleeder Adapter Notice: Pressure bleeding equipment must be of the diaphragm type. It must have a rubber diaphragm between the air supply and the brake fluid to prevent air, moisture, and other contaminants from entering the hydraulic system. 1. Inspect and fill the master cylinder reservoir to the proper level as necessary. 2. Assemble the components as shown. 3. Install the J 35589 to the master cylinder reservoir. 4. Connect the J 29532 to the J 35589. 5. Adjust the J 29532 to 35 - 70 kPa (5 - 10 psi). 6. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing brake fluid leaks. Repair any brake fluid leaks. 7. Adjust the J 29532 to 205 - 240 kPa (30 - 35 psi). Important: Use a shop cloth in order to catch escaping brake fluid. 8. Slowly open the ABS modulator brake pipe fitting (1) starting from the first pipe on the left side in order to allow the brake fluid to flow. Notice: Refer to Fastener Notice in Service Precautions. 9. Close the ABS modulator brake pipe fitting when air bubbles are no longer detected in the brake fluid. ^ Tighten the ABS modulator brake pipe fitting to 24 Nm (18 ft. lbs.). 10. Repeat Steps 8 and 9 for the remaining ABS modulator brake pipe fittings. 11. Raise and suitably support the vehicle. 12. Install the clear plastic bleeder hose to the RIGHT REAR bleeder valve: ^ For vehicles with rear drum brakes, install the clear plastic bleeder hose to the wheel cylinder bleeder valve. ^ For vehicles with rear disc brakes, install the clear plastic bleeder hose to the brake caliper bleeder valve. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 8171 13. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 14. Slowly open the bleeder valve in order to allow the brake fluid to flow. 15. Close the bleeder valve when air bubbles are no longer detected in the brake fluid. ^ For vehicles with rear drum brakes, tighten the wheel cylinder bleeder valve to 7 Nm (62 inch lbs.). ^ For vehicles with rear disc brakes, tighten the wheel cylinder bleeder valve to 11 Nm (97 inch lbs.) 16. Remove the clear plastic bleeder hose from the bleeder valve. 17. Install the clear plastic bleeder hose to the LEFT FRONT brake caliper bleeder valve. 18. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 19. Slowly open the bleeder valve in order to allow the brake fluid to flow. 20. Close the bleeder valve when air bubbles are no longer detected in the brake fluid. ^ Tighten the brake caliper bleeder valve to 13 Nm (115 inch lbs.). 21. Remove the clear plastic bleeder hose from the bleeder valve. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 8172 22. Install the clear plastic bleeder hose to the LEFT REAR bleeder valve. ^ For vehicles with rear drum brakes, install the clear plastic bleeder hose to the wheel cylinder bleeder valve. ^ For vehicles with rear disc brakes, install the clear plastic bleeder hose to the brake caliper bleeder valve. 23. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 24. Slowly open the bleeder valve in order to allow the brake fluid to flow. 25. Close the bleeder valve when air bubbles are no longer detected in the brake fluid. ^ For vehicles with rear drum brakes, tighten the wheel cylinder bleeder valve to 7 Nm (62 inch lbs.). ^ For vehicles with rear disc brakes, tighten the wheel cylinder bleeder valve to 11 Nm (97 inch lbs.) 26. Remove the clear plastic bleeder hose from the bleeder valve. 27. Install the clear plastic bleeder hose to the RIGHT FRONT brake caliper bleeder valve. 28. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 29. Slowly open the bleeder valve in order to allow the brake fluid to flow. 30. Close the bleeder valve when air bubbles are no longer detected in the brake fluid. ^ Tighten the brake caliper bleeder valve to 13 Nm (115 inch lbs.). 31. Remove the clear plastic bleeder hose from the bleeder valve. 32. Lower the vehicle. 33. Remove the J 35589 from the master cylinder reservoir. 34. Inspect and fill the master cylinder reservoir to the proper level as necessary. Refer to Master Cylinder Reservoir Filling. 35. Install the master cylinder reservoir cap. 36. Start the engine and allow the engine to run for at least 10 seconds. 37. Turn the ignition OFF. 38. Inspect the brake pedal feel and the brake pedal travel. Refer to Brake Pedal Travel. ^ If the brake pedal feels firm and constant and the brake pedal travel does not exceed specifications, proceed to Step 39. ^ If the pedal feels soft or the brake pedal travel exceeds specifications, DO NOT DRIVE THE VEHICLE. Go to Step 40. 39. Start the engine and inspect the brake pedal feel. ^ If the brake pedal still feels firm, got to Step 42. ^ If the brake pedal feels soft, DO NOT DRIVE THE VEHICLE. proceed to Step 40. 40. Use the scan tool in order to perform the automated bleed procedure. Refer to Automated Bleed Procedure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 8173 41. Ensure that the unacceptable brake pedal feel/travel is not caused by misadjusted brake linings or other mechanical failures, then repeat the Brake System Pressure Bleeding procedure. Proceed to Step 1. Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury. 42. Road test the vehicle. Make several normal (non-ABS) stops from a moderate speed in order to ensure proper brake system function. Allow adequate brake system cooling time between stops. Brake System Manual Bleeding Procedure Notice: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring, cables, or electric connectors. Brake fluid will damage the paint and the electrical connections. It any fluid is spilled on the vehicle, flush the area to lessen the damage. Important: This procedure may require the help of an assistant to apply the brake pedal while the bleeder valves are opened and closed. Important: Ensure that the master cylinder brake fluid level does not drop to the bottom of the master cylinder reservoir. You will be instructed to Inspect and fill the master cylinder reservoir at times during this procedure. However, the actual frequency of master cylinder reservoir filling REQUIRED will depend on the amount of fluid that is released. If the brake fluid level drops to the bottom of the master cylinder reservoir, start the bleed procedure again at Step 1. 1. Inspect and fill the master cylinder reservoir to the proper level as necessary. Refer to Master Cylinder Reservoir Filling. Important: Use a shop cloth in order to catch escaping brake fluid. 2. Slowly open the ABS modulator brake pipe fitting (1) starting from the first pipe on the left side in order to allow the brake fluid to flow. 3. Press and hold the brake pedal approximately 75 percent of a full stroke. Notice: Refer to Fastener Notice in Service Precautions. 4. Close the ABS modulator brake pipe fitting when air bubbles are no longer detected in the brake fluid. ^ Tighten the ABS modulator brake pipe fitting to 24 Nm (18 ft. lbs.). 5. Repeat Steps 2 and 3 for the remaining ABS modulator brake pipe fittings. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 8174 6. Inspect and fill the master cylinder reservoir to the proper level as necessary. 7. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 8. Install the clear plastic bleeder hose to the RIGHT REAR bleeder valve. ^ For vehicles with rear drum brakes, install the clear plastic bleeder hose to the wheel cylinder bleeder valve. ^ For vehicles with rear disc brakes, install the clear plastic bleeder hose to the brake caliper bleeder valve. 9. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 10. Open the bleeder valve. 11. Press and hold the brake pedal approximately 75 percent of a full stroke. 12. Close the bleeder valve. 13. Release the brake pedal. 14. Repeat Steps 10 through 13 until air bubbles are no longer detected in the brake fluid. ^ For vehicles with rear drum brakes, tighten the wheel cylinder bleeder valve to 7 Nm (62 inch lbs.). ^ For vehicles with rear disc brakes, tighten the wheel cylinder bleeder valve to 11 Nm (97 inch lbs.) 15. Remove the clear plastic bleeder hose from the bleeder valve. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 8175 16. Install the clear plastic bleeder hose to the LEFT FRONT brake caliper bleeder valve. 17. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 18. Open the bleeder valve. 19. Press and hold the brake pedal approximately 75 percent of a full stroke. 20. Close the bleeder valve. 21. Release the brake pedal. 22. Repeat Steps 18 through 21 until air bubbles are no longer detected in the brake fluid. ^ Tighten the brake caliper bleeder valve to 13 Nm (115 inch lbs.). 23. Remove the clear plastic bleeder hose from the bleeder valve. 24. Install the clear plastic bleeder hose to the LEFT REAR bleeder valve. ^ For vehicles with rear drum brakes, install the clear plastic bleeder hose to the wheel cylinder bleeder valve. ^ For vehicles with rear disc brakes, install the clear plastic bleeder hose to the brake caliper bleeder valve. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 8176 25. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 26. Open the bleeder valve. 27. Press and hold the brake pedal approximately 75 percent of a full stroke. 28. Close the bleeder valve. 29. Release the brake pedal. 30. Repeat Steps 26 through 29 until air bubbles are no longer detected in the brake fluid. ^ For vehicles with rear drum brakes, tighten the wheel cylinder bleeder valve to 7 Nm (62 inch lbs.). ^ For vehicles with rear disc brakes, tighten the wheel cylinder bleeder valve to 11 Nm (97 inch lbs.). 31. Remove the clear plastic bleeder hose from the bleeder valve. 32. Install the clear plastic bleeder hose to the RIGHT FRONT brake caliper bleeder valve. 33. Submerge the opposite end of the clear plastic bleeder hose in a clean container partially filled with clean brake fluid. 34. Open the bleeder valve. 35. Press and hold the brake pedal approximately 75 percent of a full stroke. 36. Close the bleeder valve. 37. Release the brake pedal. 38. Repeat Steps 34 through 37 until air bubbles are no longer detected in the brake fluid. ^ Tighten the brake caliper bleeder valve to 13 Nm (115 inch lbs.). 39. Remove the clear plastic bleeder hose from the bleeder valve. 40. Lower the vehicle. 41. Remove the brake fluid reservoir cover. 42. Inspect the brake fluid level in the reservoir. 43. Install the brake fluid reservoir cover. 44. Turn the ignition switch to the RUN position, then turn off the engine. Apply the brake pedal with moderate force and hold the pedal. Note the pedal travel and feel. 45. If the pedal feels firm and constant and pedal travel is not excessive, start the engine. With the engine running, recheck the pedal travel. 46. If the pedal feel is still firm and constant and pedal travel is not excessive, perform a vehicle road test. Make several normal (non-ABS) stops from a moderate speed in order to ensure proper brake system function. 47. If pedal feel is soft or has excessive travel either initially or after engine start, refer to Automated Bleed Procedure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Automated Bleed Procedure > Page 8177 48. Repeat the manual bleeding procedure, starting at Step 1. Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury. 49. Perform a vehicle road test. Make several normal (non-ABS) stops from a moderate speed in order to ensure proper brake system function. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest: > 01-05-23-011A > Feb > 02 > Brakes - Rattling Noise Brake Caliper: Customer Interest Brakes - Rattling Noise File In Section: 05 - Brakes Bulletin No.: 01-05-23-O11A Date: February, 2002 TECHNICAL Subject: Rattle Type Noise Coming from Front of Vehicle (Install Front Brake Caliper Service Kit) Models: 2000-01 Buick Century, Regal 2000-01 Chevrolet Impala, Monte Carlo, Venture 2000-01 Oldsmobile Intrigue, Silhouette 2000-01 Pontiac Grand Prix, Montana This bulletin is being revised to remove Chevrolet Lumina from the Models section and to update the condition information. Please discard Corporate Bulletin Number 01-05-23-11 (Section 05 Brakes). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment about a rattle type noise coming from the front of the vehicle. This noise usually occurs at vehicle speeds under 48 km/h (30 mph) and while driving over bumps. The noise can usually be eliminated by a light application of the brake pedal. Cause This condition may be caused by too much clearance between the front brake caliper bracket and the caliper pins in the bottom of the bracket bores. Correction Install front brake caliper service kits to both sides of the vehicle using the following service procedure. Each kit contains 2 pins, 2 boots, and 2 packets of grease. Service Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove both the front tire and wheel assemblies. 3. Hand tighten 2 wheel nuts to retain the rotor to the hub. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest: > 01-05-23-011A > Feb > 02 > Brakes - Rattling Noise > Page 8186 4. Install a large C-clamp (2) over the top of the brake caliper and against the back of the outboard brake pad. 5. Tighten the C-clamp until the caliper piston is pushed into the caliper bore enough to slide the caliper off the rotor. 6. Remove the C-clamp from the caliper. 7. Remove the caliper pin bolts (3) and discard. New bolts are supplied with the service kit. 8. Remove the caliper (1) from the caliper bracket (2) and support the caliper with heavy mechanic's wire, or equivalent. 9. Using a flat bladed tool or punch, carefully tap the caliper pin boots from the brake caliper bracket and discard. 10. Remove and discard the bushings from the brake caliper bracket bores. Carefully insert a small screwdriver into the brake caliper bracket bore, then rotate and pull the bushing outward to remove. 11. Remove the brake pads from the brake caliper bracket. 12. Thoroughly clean the brake caliper bracket bores of all lubricant. 13. Install the brake pads to the brake caliper bracket. 14. Lubricate the brake caliper bracket bores. Divide the large packet of grease, P/N 18046532; put one-half packet into each bore. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest: > 01-05-23-011A > Feb > 02 > Brakes - Rattling Noise > Page 8187 15. Lubricate the new caliper pin boots. Use the small packet of grease, P/N 18046645, only on the bottom internal threads (2). 16. Install the new caliper pin boots into the caliper pin bores (3) on the bracket. Carefully tap boots into bores using a deep well socket or equivalent. 17. Install the caliper over the rotor and onto the caliper bracket. Ensure that the caliper pin boots are not pinched. Important: The leading caliper pin, or top pin, has a bushing as part of the assembly. The trailing caliper pin, or bottom pin, is a solid design. 18. Install the new caliper pin bolts (1). It is important to note which caliper pin is designed for the correct bore. The leading caliper pin, or top pin, has a bushing as part of the assembly. The trailing caliper pin, or bottom pin, is a solid design. Ensure that the bolt boots fit securely in the groove of the pin bolts. Be sure not to pinch or tear the boots. If the boots are damaged, they must be replaced. Tighten Tighten the bolts to 95 N.m (70 lb ft). 19. Remove the 2 wheel nuts retaining the rotor to the hub. 20. Repeat the above steps for the other side. 21. Install both the front tire and wheel assemblies. Tighten the wheel nuts using the J 39544 kit. 22. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest: > 01-05-23-011A > Feb > 02 > Brakes - Rattling Noise > Page 8188 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 01-05-23-011A > Feb > 02 > Brakes - Rattling Noise Brake Caliper: All Technical Service Bulletins Brakes - Rattling Noise File In Section: 05 - Brakes Bulletin No.: 01-05-23-O11A Date: February, 2002 TECHNICAL Subject: Rattle Type Noise Coming from Front of Vehicle (Install Front Brake Caliper Service Kit) Models: 2000-01 Buick Century, Regal 2000-01 Chevrolet Impala, Monte Carlo, Venture 2000-01 Oldsmobile Intrigue, Silhouette 2000-01 Pontiac Grand Prix, Montana This bulletin is being revised to remove Chevrolet Lumina from the Models section and to update the condition information. Please discard Corporate Bulletin Number 01-05-23-11 (Section 05 Brakes). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment about a rattle type noise coming from the front of the vehicle. This noise usually occurs at vehicle speeds under 48 km/h (30 mph) and while driving over bumps. The noise can usually be eliminated by a light application of the brake pedal. Cause This condition may be caused by too much clearance between the front brake caliper bracket and the caliper pins in the bottom of the bracket bores. Correction Install front brake caliper service kits to both sides of the vehicle using the following service procedure. Each kit contains 2 pins, 2 boots, and 2 packets of grease. Service Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove both the front tire and wheel assemblies. 3. Hand tighten 2 wheel nuts to retain the rotor to the hub. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 01-05-23-011A > Feb > 02 > Brakes - Rattling Noise > Page 8194 4. Install a large C-clamp (2) over the top of the brake caliper and against the back of the outboard brake pad. 5. Tighten the C-clamp until the caliper piston is pushed into the caliper bore enough to slide the caliper off the rotor. 6. Remove the C-clamp from the caliper. 7. Remove the caliper pin bolts (3) and discard. New bolts are supplied with the service kit. 8. Remove the caliper (1) from the caliper bracket (2) and support the caliper with heavy mechanic's wire, or equivalent. 9. Using a flat bladed tool or punch, carefully tap the caliper pin boots from the brake caliper bracket and discard. 10. Remove and discard the bushings from the brake caliper bracket bores. Carefully insert a small screwdriver into the brake caliper bracket bore, then rotate and pull the bushing outward to remove. 11. Remove the brake pads from the brake caliper bracket. 12. Thoroughly clean the brake caliper bracket bores of all lubricant. 13. Install the brake pads to the brake caliper bracket. 14. Lubricate the brake caliper bracket bores. Divide the large packet of grease, P/N 18046532; put one-half packet into each bore. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 01-05-23-011A > Feb > 02 > Brakes - Rattling Noise > Page 8195 15. Lubricate the new caliper pin boots. Use the small packet of grease, P/N 18046645, only on the bottom internal threads (2). 16. Install the new caliper pin boots into the caliper pin bores (3) on the bracket. Carefully tap boots into bores using a deep well socket or equivalent. 17. Install the caliper over the rotor and onto the caliper bracket. Ensure that the caliper pin boots are not pinched. Important: The leading caliper pin, or top pin, has a bushing as part of the assembly. The trailing caliper pin, or bottom pin, is a solid design. 18. Install the new caliper pin bolts (1). It is important to note which caliper pin is designed for the correct bore. The leading caliper pin, or top pin, has a bushing as part of the assembly. The trailing caliper pin, or bottom pin, is a solid design. Ensure that the bolt boots fit securely in the groove of the pin bolts. Be sure not to pinch or tear the boots. If the boots are damaged, they must be replaced. Tighten Tighten the bolts to 95 N.m (70 lb ft). 19. Remove the 2 wheel nuts retaining the rotor to the hub. 20. Repeat the above steps for the other side. 21. Install both the front tire and wheel assemblies. Tighten the wheel nuts using the J 39544 kit. 22. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 01-05-23-011A > Feb > 02 > Brakes - Rattling Noise > Page 8196 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 01-05-23-006A > Jun > 01 > Brake Calipers - Revised Fastener Requirements Brake Caliper: All Technical Service Bulletins Brake Calipers - Revised Fastener Requirements File In Section: 05 - Brakes Bulletin No.: 01-05-23-006A Date: June, 2001 SERVICE MANUAL UPDATE Subject: Revised Fastener Requirements for Front and Rear Brake Caliper Bracket Replacement Models: 1997-2001 Buick Century, Regal 1997-2001 Buick Regal (Export China) 1997-2001 Chevrolet Trans Sport (Export China), Venture 2000-2001 Chevrolet Impala, Monte Carlo 1998-2001 Oldsmobile Intrigue 1997-1998 Pontiac Trans Sport 1997-2001 Pontiac Grand Prix 1999-2001 Pontiac Montana This bulletin is being revised to update the model information. Please discard Corporate Bulletin Number 01-05-23-006 (Section 05 - Brakes). This bulletin is being issued to revise the fastener requirements for the front and rear brake caliper bracket replacement procedures in the Disc-Brake sub-section of Brakes in the appropriate Service Manual. Please use the following to replace the existing information in the Service Manual. This information has been updated within SI2000. If you are using a paper version of this Service Manual, please mark a reference to this bulletin on the affected page in the Disc-Brake sub-section of the Service Manual. Front Brake Caliper Bracket Replacement (All Above Listed Vehicles) 1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanics wire or equivalent. It is not necessary to disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the front brake pads. 3. Remove the caliper bracket bolts (2). 4. Remove the caliper bracket (1). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 01-05-23-006A > Jun > 01 > Brake Calipers - Revised Fastener Requirements > Page 8201 Important: To ensure that the proper clamp load will be present when installed, it is imperative that the threads on the caliper bracket bolts, as well as the mounting holes in the knuckle, be cleaned of all debris and inspected before proceeding with installation. 5. Clean and visually inspect threads of the caliper bracket bolts (2) and mounting holes in the knuckle. 6. Apply LOCTITE(R) THREAD LOCKER 272 (GM P/N 12345493) or equivalent to the threads of the brake caliper bracket bolts (2). 7. Install the caliper bracket (1) with the bracket bolts (2). Tighten Tighten the caliper bracket bolts to 180 N.m (133 lb ft). 8. Install the front brake pads. 9. Install the caliper. Rear Brake Caliper Bracket Replacement (See Vehicles Listed Below) ^ 1999-2001 Buick Century, Regal ^ 1999-2001 Buick Regal (Export China) ^ 2000-2001 Chevrolet Impala, Monte Carlo ^ 2000-2001 Chevrolet Trans Sport (Export China) ^ 1998-2001 Oldsmobile Intrigue ^ 1997-2001 Pontiac Grand Prix 1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanics wire or equivalent. It is not necessary to disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the rear brake pads. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 01-05-23-006A > Jun > 01 > Brake Calipers - Revised Fastener Requirements > Page 8202 3. Remove the caliper bracket bolts (2). 4. Remove the caliper bracket (1). Important: To ensure that the proper clamp load will be present when installed, it is imperative that the threads on the caliper bracket bolts, as well as the mounting holes in the knuckle, be cleaned of all debris and inspected before proceeding with installation. 5. Clean and visually inspect threads of the caliper bracket bolts (2) and mounting holes in the knuckle. 6. Apply LOCTITE(R) THREAD LOCKER 272 (GM P/N 12345493) or equivalent to the threads of the brake caliper bracket bolts (2). 7. Install the caliper bracket (1) with the bracket bolts (2). Tighten Tighten the caliper bracket bolts to 115 N.m (85 lb ft). 8. Install the rear brake pads. 9. Install the caliper. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 01-05-23-003 > Mar > 01 > Front/Rear Brakes - Revised Tool Requirements Technical Service Bulletin # 01-05-23-003 Date: 010301 Front/Rear Brakes - Revised Tool Requirements File In Section: 05 - Brakes Bulletin No.: 01-05-23-003 Date: March, 2001 SERVICE MANUAL UPDATE Subject: Revised Tool Requirements for Front and Rear Brake Caliper Overhaul Models: 1997-2001 Buick Park Avenue, Regal 1997-2001 Buick Regal (Export China) 2000-2001 Buick LeSabre 1997-2001 Cadillac DeVille, Seville 2000-2001 Cadillac Eldorado 1997-2001 Chevrolet Trans Sport (Export China), Venture 2000-2001 Chevrolet Impala, Lumina, Monte Carlo 1997-2001 Oldsmobile Aurora, Silhouette 1998-2001 Oldsmobile Intrigue 1997-2001 Pontiac Grand Prix, Montana, Trans Sport 2000-2001 Pontiac Bonneville This bulletin is being issued to revise the tool requirements for the front and rear brake caliper overhaul procedures in the Disc-Brake sub-section of Brakes in the appropriate Service Manual. Please use the following to replace the existing information in the Service Manual. This information has been updated within SI2000. If you are using a paper version of this Service Manual, please mark a reference to this bulletin on the affected page in the Disc Brake sub-section of the Service Manual. DISCLAIMER Front Brake Caliper Overhaul Procedure (All Above Listed Vehicles) Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury. Notice: Use clean cloths to pad the interior of the caliper housing during piston removal. Use just enough air to ease the piston out of the bores. If the pistons are blown out, even with the padding provided it may be damaged. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 01-05-23-003 > Mar > 01 > Front/Rear Brakes - Revised Tool Requirements > Page 8207 1. Remove the front brake caliper from the vehicle. 2. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole. 3. Using a small wooden or plastic tool, remove the caliper piston seal (2) from the seal counterbore in the caliper (1) and discard the boot seal. 4. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore and discard the piston seal. 5. Remove the bleeder valve (5) and cap (6) from the caliper (1). Important: Do not use abrasives to clean the brake caliper piston. 6. Clean the brake caliper piston bore and seal counterbore and the caliper piston with denatured alcohol, or equivalent. 7. Dry the caliper piston bore and counterbore and the piston with non-lubricated, filtered air. 8. Inspect the caliper bore for cracks, scoring, pitting, excessive rust and/or excessive corrosion. 9. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 10. If cracks, scoring, pitting, excessive rust and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 11. Inspect the caliper piston for cracks, scoring and/or damage to the finished surface area. Replace the caliper piston if any of these conditions exist. 12. Lubricate the new piston seal with Delco Supreme 11(R), P/N 12377967 (in Canada use P/N 992668), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 13. Install the lubricated new piston seal into the caliper bore. 14. Install the caliper piston into the caliper bore. Press the piston to the bottom of the bore. 15. Install the new piston dust boot seal over the piston. 16. Use J-35777 to fully seat the caliper piston seal into the counterbore. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 01-05-23-003 > Mar > 01 > Front/Rear Brakes - Revised Tool Requirements > Page 8208 17. Install the bleeder valve and cap to the caliper and tighten the valve securely. 18. Install the front brake caliper to the vehicle. Rear Brake Caliper Overhaul Procedure (See Vehicles Listed Below) ^ 1999-2001 Buick Regal ^ 1999-2001 Buick Regal (Export China) ^ 2000-2001 Chevrolet Impala, Monte Carlo, Trans Sport (Export China) ^ 1998-2001 Oldsmobile Intrigue ^ 1997-2001 Pontiac Grand Prix Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury. Notice: Use clean cloths to pad the interior of the caliper housing during piston removal. Use just enough air to ease the piston out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. 1. Remove the rear brake caliper from the vehicle. 2. Remove the bleeder valve and cap from the caliper housing. 3. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole. 4. Remove the retaining ring that secures the dust boot to the caliper housing. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 01-05-23-003 > Mar > 01 > Front/Rear Brakes - Revised Tool Requirements > Page 8209 5. Remove the piston dust boot seal (2) from the seal counterbore in the caliper. Discard the boot seal. 6. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore. Discard the piston seal. Important: Do not use abrasives to clean the brake caliper piston. 7. Clean the brake caliper piston bore and seal counterbore and the caliper piston with denatured alcohol, or equivalent. 8. Dry the caliper piston bore and counterbore and the piston with non-lubricated, filtered air. 9. Inspect the caliper bore for cracks, scoring, pitting, excessive rust and/or excessive corrosion. 10. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 11. If cracks, scoring, pitting, excessive rust and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 12. Inspect the caliper piston for cracks, scoring and/or damage to the chrome plating. Replace the caliper piston if any of these conditions exist. 13. Lubricate the new piston seal (4) with Delco Supreme 11(R), P/N 12377967 (in Canada, use P/N 992668), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Install the lubricated new piston seal (4) into the caliper bore. 15. Install the bottom half of the caliper piston (3) into the caliper bore. 16. Install the new piston dust boot seal (2) over the caliper piston (3). 17. Compress the caliper piston (3) to the bottom of the caliper bore. 18. Fully seat the piston dust boot seal (2) into caliper counterbore. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 01-05-23-003 > Mar > 01 > Front/Rear Brakes - Revised Tool Requirements > Page 8210 19. Install the retaining ring that secures the dust boot to the caliper housing. 20. Install the bleeder valve and cap to the caliper and tighten the valve securely. 21. Install the rear brake caliper to the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-05-23-006A > Jun > 01 > Brake Calipers - Revised Fastener Requirements Brake Caliper: All Technical Service Bulletins Brake Calipers - Revised Fastener Requirements File In Section: 05 - Brakes Bulletin No.: 01-05-23-006A Date: June, 2001 SERVICE MANUAL UPDATE Subject: Revised Fastener Requirements for Front and Rear Brake Caliper Bracket Replacement Models: 1997-2001 Buick Century, Regal 1997-2001 Buick Regal (Export China) 1997-2001 Chevrolet Trans Sport (Export China), Venture 2000-2001 Chevrolet Impala, Monte Carlo 1998-2001 Oldsmobile Intrigue 1997-1998 Pontiac Trans Sport 1997-2001 Pontiac Grand Prix 1999-2001 Pontiac Montana This bulletin is being revised to update the model information. Please discard Corporate Bulletin Number 01-05-23-006 (Section 05 - Brakes). This bulletin is being issued to revise the fastener requirements for the front and rear brake caliper bracket replacement procedures in the Disc-Brake sub-section of Brakes in the appropriate Service Manual. Please use the following to replace the existing information in the Service Manual. This information has been updated within SI2000. If you are using a paper version of this Service Manual, please mark a reference to this bulletin on the affected page in the Disc-Brake sub-section of the Service Manual. Front Brake Caliper Bracket Replacement (All Above Listed Vehicles) 1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanics wire or equivalent. It is not necessary to disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the front brake pads. 3. Remove the caliper bracket bolts (2). 4. Remove the caliper bracket (1). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-05-23-006A > Jun > 01 > Brake Calipers - Revised Fastener Requirements > Page 8216 Important: To ensure that the proper clamp load will be present when installed, it is imperative that the threads on the caliper bracket bolts, as well as the mounting holes in the knuckle, be cleaned of all debris and inspected before proceeding with installation. 5. Clean and visually inspect threads of the caliper bracket bolts (2) and mounting holes in the knuckle. 6. Apply LOCTITE(R) THREAD LOCKER 272 (GM P/N 12345493) or equivalent to the threads of the brake caliper bracket bolts (2). 7. Install the caliper bracket (1) with the bracket bolts (2). Tighten Tighten the caliper bracket bolts to 180 N.m (133 lb ft). 8. Install the front brake pads. 9. Install the caliper. Rear Brake Caliper Bracket Replacement (See Vehicles Listed Below) ^ 1999-2001 Buick Century, Regal ^ 1999-2001 Buick Regal (Export China) ^ 2000-2001 Chevrolet Impala, Monte Carlo ^ 2000-2001 Chevrolet Trans Sport (Export China) ^ 1998-2001 Oldsmobile Intrigue ^ 1997-2001 Pontiac Grand Prix 1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanics wire or equivalent. It is not necessary to disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the rear brake pads. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-05-23-006A > Jun > 01 > Brake Calipers - Revised Fastener Requirements > Page 8217 3. Remove the caliper bracket bolts (2). 4. Remove the caliper bracket (1). Important: To ensure that the proper clamp load will be present when installed, it is imperative that the threads on the caliper bracket bolts, as well as the mounting holes in the knuckle, be cleaned of all debris and inspected before proceeding with installation. 5. Clean and visually inspect threads of the caliper bracket bolts (2) and mounting holes in the knuckle. 6. Apply LOCTITE(R) THREAD LOCKER 272 (GM P/N 12345493) or equivalent to the threads of the brake caliper bracket bolts (2). 7. Install the caliper bracket (1) with the bracket bolts (2). Tighten Tighten the caliper bracket bolts to 115 N.m (85 lb ft). 8. Install the rear brake pads. 9. Install the caliper. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-05-23-003 > Mar > 01 > Front/Rear Brakes - Revised Tool Requirements Technical Service Bulletin # 01-05-23-003 Date: 010301 Front/Rear Brakes - Revised Tool Requirements File In Section: 05 - Brakes Bulletin No.: 01-05-23-003 Date: March, 2001 SERVICE MANUAL UPDATE Subject: Revised Tool Requirements for Front and Rear Brake Caliper Overhaul Models: 1997-2001 Buick Park Avenue, Regal 1997-2001 Buick Regal (Export China) 2000-2001 Buick LeSabre 1997-2001 Cadillac DeVille, Seville 2000-2001 Cadillac Eldorado 1997-2001 Chevrolet Trans Sport (Export China), Venture 2000-2001 Chevrolet Impala, Lumina, Monte Carlo 1997-2001 Oldsmobile Aurora, Silhouette 1998-2001 Oldsmobile Intrigue 1997-2001 Pontiac Grand Prix, Montana, Trans Sport 2000-2001 Pontiac Bonneville This bulletin is being issued to revise the tool requirements for the front and rear brake caliper overhaul procedures in the Disc-Brake sub-section of Brakes in the appropriate Service Manual. Please use the following to replace the existing information in the Service Manual. This information has been updated within SI2000. If you are using a paper version of this Service Manual, please mark a reference to this bulletin on the affected page in the Disc Brake sub-section of the Service Manual. DISCLAIMER Front Brake Caliper Overhaul Procedure (All Above Listed Vehicles) Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury. Notice: Use clean cloths to pad the interior of the caliper housing during piston removal. Use just enough air to ease the piston out of the bores. If the pistons are blown out, even with the padding provided it may be damaged. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-05-23-003 > Mar > 01 > Front/Rear Brakes - Revised Tool Requirements > Page 8222 1. Remove the front brake caliper from the vehicle. 2. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole. 3. Using a small wooden or plastic tool, remove the caliper piston seal (2) from the seal counterbore in the caliper (1) and discard the boot seal. 4. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore and discard the piston seal. 5. Remove the bleeder valve (5) and cap (6) from the caliper (1). Important: Do not use abrasives to clean the brake caliper piston. 6. Clean the brake caliper piston bore and seal counterbore and the caliper piston with denatured alcohol, or equivalent. 7. Dry the caliper piston bore and counterbore and the piston with non-lubricated, filtered air. 8. Inspect the caliper bore for cracks, scoring, pitting, excessive rust and/or excessive corrosion. 9. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 10. If cracks, scoring, pitting, excessive rust and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 11. Inspect the caliper piston for cracks, scoring and/or damage to the finished surface area. Replace the caliper piston if any of these conditions exist. 12. Lubricate the new piston seal with Delco Supreme 11(R), P/N 12377967 (in Canada use P/N 992668), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 13. Install the lubricated new piston seal into the caliper bore. 14. Install the caliper piston into the caliper bore. Press the piston to the bottom of the bore. 15. Install the new piston dust boot seal over the piston. 16. Use J-35777 to fully seat the caliper piston seal into the counterbore. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-05-23-003 > Mar > 01 > Front/Rear Brakes - Revised Tool Requirements > Page 8223 17. Install the bleeder valve and cap to the caliper and tighten the valve securely. 18. Install the front brake caliper to the vehicle. Rear Brake Caliper Overhaul Procedure (See Vehicles Listed Below) ^ 1999-2001 Buick Regal ^ 1999-2001 Buick Regal (Export China) ^ 2000-2001 Chevrolet Impala, Monte Carlo, Trans Sport (Export China) ^ 1998-2001 Oldsmobile Intrigue ^ 1997-2001 Pontiac Grand Prix Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury. Notice: Use clean cloths to pad the interior of the caliper housing during piston removal. Use just enough air to ease the piston out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. 1. Remove the rear brake caliper from the vehicle. 2. Remove the bleeder valve and cap from the caliper housing. 3. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole. 4. Remove the retaining ring that secures the dust boot to the caliper housing. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-05-23-003 > Mar > 01 > Front/Rear Brakes - Revised Tool Requirements > Page 8224 5. Remove the piston dust boot seal (2) from the seal counterbore in the caliper. Discard the boot seal. 6. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore. Discard the piston seal. Important: Do not use abrasives to clean the brake caliper piston. 7. Clean the brake caliper piston bore and seal counterbore and the caliper piston with denatured alcohol, or equivalent. 8. Dry the caliper piston bore and counterbore and the piston with non-lubricated, filtered air. 9. Inspect the caliper bore for cracks, scoring, pitting, excessive rust and/or excessive corrosion. 10. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 11. If cracks, scoring, pitting, excessive rust and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 12. Inspect the caliper piston for cracks, scoring and/or damage to the chrome plating. Replace the caliper piston if any of these conditions exist. 13. Lubricate the new piston seal (4) with Delco Supreme 11(R), P/N 12377967 (in Canada, use P/N 992668), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Install the lubricated new piston seal (4) into the caliper bore. 15. Install the bottom half of the caliper piston (3) into the caliper bore. 16. Install the new piston dust boot seal (2) over the caliper piston (3). 17. Compress the caliper piston (3) to the bottom of the caliper bore. 18. Fully seat the piston dust boot seal (2) into caliper counterbore. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 01-05-23-003 > Mar > 01 > Front/Rear Brakes - Revised Tool Requirements > Page 8225 19. Install the retaining ring that secures the dust boot to the caliper housing. 20. Install the bleeder valve and cap to the caliper and tighten the valve securely. 21. Install the rear brake caliper to the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Fastener Tightening Specifications Brake Caliper: Specifications Front Brakes Caliper Bolts 63 ft.lb Bleeder Valve 115 in.lb Caliper Bracket Bolts 133 ft.lb Rear Brakes Caliper Bolt 32 ft.lb Caliper Bracket Bolts 93 ft.lb Bleeder Valve 97 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Fastener Tightening Specifications > Page 8228 Brake Caliper: Specifications Bleeder Valve (Front Caliper) 115 in.lb Bleeder Valve (Rear Caliper) 62 in.lb Caliper Bore Diameter 1.654 in Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement Brake Caliper: Service and Repair Brake Caliper Bracket Replacement Brake Caliper Bracket Replacement - Front Removal Procedure Important: Do not disconnect the brake hose from the caliper. Support or hang the caliper. Do not let the caliper hang from the brake hose. 1. Remove the caliper. Refer to Brake Caliper Replacement (Front). Caution: These fasteners MUST be replaced with new fasteners anytime they become loose or are removed. Failure to replace these fasteners after they become loose or are removed may cause loss of vehicle control and personal injury. Important: The NEW brake caliper bolts come with an encapsulated thread compound already on the bolt. 2. Remove the caliper bracket bolts (2). 3. Remove the caliper bracket (1). 4. Remove the following components from the bracket (1): ^ The boot bolts (2) ^ The bushings 5. Inspect the bracket (1) for cracks. 6. Replace the bracket (1) if necessary. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8231 1. Lubricate the following components with silicone grease: ^ The bolt boots (2) ^ The bushings 2. Install the following components into the caliper bracket (1): ^ The bolt boots (2) ^ The bushings Notice: Refer to Fastener Notice in Service Precautions. 3. Install the caliper bracket with the bracket bolts. ^ Tighten the caliper bracket bolts to 185 Nm (137 ft. lbs.). 4. Install the caliper. Refer to Brake Caliper Replacement (Front). Brake Caliper Bracket Replacement - Rear Removal Procedure Important: Do not disconnect the brake hose from the caliper. Support or hang the caliper. Do not let the caliper hang from the brake hose. 1. Remove the caliper. Refer to Brake Caliper Replacement (Rear). Caution: These fasteners MUST be replaced with new fasteners anytime they become loose or are removed. Failure to replace these fasteners after they become loose or are removed may cause loss of vehicle control and personal injury. Important: The NEW brake caliper bolts come with an encapsulated thread compound already on the bolt. 2. Remove the caliper bracket bolts (2). 3. Remove the caliper bracket (1). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8232 4. Remove the following components from the bracket (1): ^ The bolt boots (2) ^ The bushings 5. Inspect the bracket (1) for cracks. 6. Replace the bracket (1) if necessary. Installation Procedure 1. Lubricate the following components with silicone grease: ^ The bolt boots (2) ^ The bushings 2. Install the following components into the caliper bracket (1): ^ The bolt boots (2) ^ The bushings Notice: Refer to Fastener Notice in Service Precautions. 3. Install the caliper bracket with the bracket bolts. ^ Tighten the caliper bracket bolts to 125 Nm (92 ft. lbs.). 4. Install the caliper. Refer to Brake Caliper Replacement (Rear). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8233 Brake Caliper: Service and Repair Brake Caliper Overhaul Front Disassembly Procedure 1. Remove the caliper. Refer to Brake Caliper Replacement (Front). Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury. Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. 2. Remove the piston. Blow compressed air into the caliper inlet hole. The piston will come out through the piston boot. 3. Inspect the piston for the following conditions: ^ Scoring ^ Nicks ^ Corrosion ^ Worn or damaged chrome plating Replace the piston if any of the above conditions are found. 4. Remove the caliper boot (2). Do not scratch the housing bore. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8234 Notice: Do not use a metal tool for seal removal. Damage to the caliper bore or the seal grooves can result. 5. Remove the piston seal (4) from the groove in the caliper bore, Use a small wooden or plastic tool. 6. Inspect the caliper bore and the seal grooves for the following conditions: ^ Scoring ^ Nicks ^ Corrosion ^ Wear 7. Use a crocus cloth in order to polish out light corrosion. 8. Replace the caliper housing (3) if corrosion in and around the seal groove cannot be cleaned with a crocus cloth, 9. Inspect the bolt boots (2) for the following conditions: ^ Cuts ^ Tears ^ Deterioration 10. Replace any damaged boots (2). 11. Inspect the caliper bolts for corrosion or damage. Replace any corroded bolts. Do not attempt to polish away corrosion. 12. Inspect the seal groove in the caliper bore for nicks or burrs. Replace the caliper if the seal groove is damaged. 13. Remove the bleeder valve cap and the bleeder valve from the caliper housing. 14. Clean all the parts in clean, denatured alcohol. 15. Dry all the parts with filtered, non-lubricated compressed air. 16. Blow out all the passages in the caliper housing and the bleeder valve. Use filtered, non-lubricated compressed air. Assembly Procedure ^ Tools Required J 36349 Front Dust Boot Seal Installer Notice: Refer to Fastener Notice in Service Precautions. 1. Install the bleeder valve (2) and the bleeder valve cap (1) to the caliper housing. ^ Tighten the bleeder valve to 13 Nm (115 inch lbs.). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8235 2. Install a new lubricated piston seal (4) into the caliper bore grooves. Ensure that the piston seal is not twisted. 3. Install the lubricated boot (1) onto the piston (2). 4. Lubricate the piston OD with clean brake fluid. 5. Install the piston and the boot into the bore of the caliper. Push the piston to the bottom of the bore. 6. Seat the caliper boot in the caliper housing (1) counterbore using J 36349. 7. Install the caliper. Refer to Brake Caliper Replacement (Front) or Brake Caliper Replacement (Rear). Rear Disassembly Procedure 1. Remove the caliper. Refer to Brake Caliper Replacement (Rear). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8236 Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury. Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. 2. Remove the piston. Blow compressed air into the caliper inlet hole. The piston will come out through the piston boot. 3. Inspect the piston for the following conditions: ^ Scoring ^ Nicks ^ Corrosion ^ Worn or damaged chrome plating Replace the piston if any of the above conditions are found. 4. Remove the caliper boot (2). Do not scratch the housing bore. Notice: Do not use a metal tool for seal removal. Damage to the caliper bore or the seal grooves can result. 5. Remove the piston seal (4) from the groove in the caliper bore. Use a small wooden or plastic tool. 6. Inspect the caliper bore and the seal grooves for the following conditions: ^ Scoring ^ Nicks ^ Corrosion ^ Wear 7. Use a crocus cloth in order to polish out light corrosion. 8. Replace the caliper housing (3) if corrosion in and around the seal groove cannot be cleaned with a crocus cloth. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8237 9. Inspect the bolt boots (2) for the following conditions: ^ Cuts ^ Tears ^ Deterioration 10. Replace any damaged boots (2). 11. Inspect the caliper bolts for corrosion or damage. Replace any corroded bolts. Do not attempt to polish away corrosion. 12. Inspect the seal groove in the caliper bore for nicks or burrs. Replace the caliper if the seal groove is damaged. 13. Remove the bleeder valve cap (1) and the bleeder valve (2) from the caliper housing (3). 14. Clean all the parts in clean, denatured alcohol. 15. Dry all the parts with filtered, non-lubricated compressed air. 16. Blow out all the passages in the caliper housing and the bleeder valve. Use filtered, non-lubricated compressed air. Assembly Procedure ^ Tools Required J 36349 Front Dust Boot Seal Installer Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8238 1. Install the bleeder valve and the bleeder valve cap to the caliper housing. ^ Tighten the bleeder valve to 11 Nm (97 inch lbs.). 2. Lubricate piston seal with clean brake fluid. 3. Install a new piston seal into the caliper bore grooves. Ensure that the piston seal is not twisted. 4. Install the lubricated boot (1) onto the piston (2). 5. Lubricate the piston OD with clean brake fluid. 6. Install the piston and the boot into the bore of the caliper. Push the piston to the bottom of the bore. 7. Seat the caliper boot in the caliper housing (1) counterbore using J 36349. 8. Install the caliper. Refer to Brake Caliper Replacement (Rear). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8239 Brake Caliper: Service and Repair Brake Caliper Replacement Brake Caliper Replacement (Front) Removal Procedure Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury. 1. Remove two-thirds of the brake fluid from the master cylinder. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Mark the relationship of the wheel to the hub. 4. Remove the tires and the wheel. Refer to Tire and Wheel Removal and Installation. Install two wheel nuts to retain the rotor. 5. Push the piston (4) onto the caliper bore in order to provide clearance between the linings and the rotor. Complete the following steps: 5.1. Install a large C-clamp over the top of the caliper housing (3) and against the back of the outboard pad (1). 5.2. Slowly tighten the C-clamp until the piston (4) pushes into the caliper bore enough to slide the caliper (3) off the rotor. Do not overtighten the C-clamp. Overtightening the C-clamp will deform the outboard pad (1). Notice: Do not allow calipers to hang from the flexible hoses. Doing so can damage the hoses. 6. If you remove the caliper from the vehicle for unit repair (overhaul), then remove the brake hose bolt that attaches the inlet fitting. If only the brake pads are being replaced, do not disconnect the inlet fitting. 7. Plug the openings in the caliper housing and the pipe in order to prevent brake fluid loss and contamination. 8. Remove the caliper bolts (3). 9. Remove the caliper housing (1) from the rotor and the caliper bracket (2). 10. Inspect the bolt boots for the following conditions: ^ Cuts ^ Tears ^ Deterioration Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8240 Replace the bolt boots if damage exists. Refer to Brake Caliper Bracket Replacement (Front). 11. Inspect the piston boot for the following conditions: ^ Cuts ^ Tears ^ Deterioration Replace the piston boot in the caliper if damage exists. Refer to Brake Caliper Overhaul (Front). 12. Inspect the bolt boots in the caliper bracket for the following conditions: ^ Cuts ^ Tears ^ Deterioration Replace the bolt boots in the caliper bracket if damage exists. Refer to Brake Caliper Bracket Replacement (Front). 13. Inspect the caliper bolts (1) for corrosion or damage. If corrosion is found, use new parts, including bushings, when installing the caliper. Do not attempt to polish away corrosion. Installation Procedure 1. Install the caliper housing (1) over the rotor and the caliper bracket (2). Ensure that the bushings are in place. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8241 2. Lubricate the caliper bolts (1). Use silicone grease. Do not lubricate the threads. 3. Lubricate the two bolt boots in the caliper bracket (6). Use silicone grease. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the caliper bolts (3). Use a screwdriver in order to push the bolt boot over the shoulder of the caliper bolt. Ensure that the bolt boot fits securely in the groove of the pin bolt. ^ Tighten the caliper bolts to 85 Nm (63 ft. lbs.). Important: Replace the copper gaskets. 5. Install the brake hose bolt, if removed. ^ Tighten the brake hose bolt to 54 Nm (40 ft. lbs.). 6. Remove the wheel nuts securing the rotor to the hub. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8242 7. Install the tires and the wheels. Refer to Tire and Wheel Removal and Installation. Align the previous marks on the wheel and the hub. 8. Lower the vehicle. 9. Fill the master cylinder to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling. 10. Bleed the caliper if the inlet fitting was removed. Refer to Hydraulic Brake System Bleeding. 11. Apply the brake pedal approximately three times after bleeding, if necessary. 12. Inspect the hydraulic brake system for brake fluid leaks. Brake Caliper Replacement (Rear) Removal Procedure 1. Remove two-thirds of the brake fluid from the master cylinder. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Mark the relationship of the wheel to the hub and bearing. 4. Remove the tires and the wheel. Refer to Tire and Wheel Removal and Installation. Install two wheel nuts in order to retain the rotor. 5. Push the piston (7) onto the caliper bore (2) in order to provide clearance between the linings and the rotor. Complete the following steps: ^ Install a large C-clamp over the top of the caliper housing (15) and against the back of the outboard pad (9). ^ Slowly tighten the C-clamp until the piston (7) is pushed into the caliper bore (2) enough in order to slide the caliper (15) off the rotor. Do not overtighten the C-clamp. Overtightening will deform the outboard pad (9). 6. Remove the hose bolt attaching the inlet fitting. 7. Plug the openings in the caliper housing (15) and the pipe in order to prevent brake fluid loss and contamination. 8. Remove the caliper bolts (1 and 3). Notice: Do not allow calipers to hang from the flexible hoses. Doing so can damage the hoses. 9. Remove the caliper housing (3) from the rotor (4) and the caliper bracket (1). 10. Inspect the piston boots for the following conditions: Cuts Tears Deterioration Replace the piston boots if damage exists. Refer to Brake Caliper Overhaul (Front). 11. Inspect the caliper bracket boots for the following conditions: ^ Cuts ^ Tears Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8243 ^ Deterioration Replace the caliper bracket boots if damage exists. Refer to Brake Caliper Bracket Replacement (Front). 12. Inspect the caliper bolts (2) for corrosion or damage. If corrosion is found, use new parts, including bushings, when installing caliper. Do not attempt to polish away corrosion. Installation Procedure 1. Install the caliper (3) over the rotor (4) and the caliper bracket (1). Ensure that the bushings are in place. 2. Lubricate the caliper bolts (1 and 3). Use silicone grease. Do not lubricate the threads. 3. Lubricate the two rubber boots (13 and 4) in the caliper bracket (12). Use silicone grease. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the caliper bolts (1 and 3). Use a flat bladed tool in order to push the boot over the shoulder of the caliper bolt. Ensure that the boot is securely in the groove of the caliper bolt. ^ Tighten the caliper bolts (1 and 3) to 44 Nm (32 ft. lbs.). Important: Replace the copper gaskets. 5. Install the brake hose bolt. ^ Tighten the brake hose bolt to 54 Nm (40 ft. lbs.). 6. Remove the wheel nuts securing the rotor to the hub and bearing. 7. Install the tires and the wheels. Refer to Tire and Wheel Removal and Installation. Align the previous marks on the wheel and the hub and bearing. 8. Lower the vehicle. 9. Fill the master cylinder to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling. 10. Bleed the entire brake system. Refer to Hydraulic Brake System Bleeding. 11. Apply the brake pedal approximately three times after bleeding, in order to seat the pads against the rotor. 12. Inspect the hydraulic brake system for brake fluid leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Brake Fluid - Level & Filling Recommendations Brake Fluid: Technical Service Bulletins Brake Fluid - Level & Filling Recommendations File In Section: 05 - Brakes Bulletin No.: 00-05-22-004 Date: May, 2000 INFORMATION Subject: Brake Fluid Level and Filling Recommendations Models: 2001 and Prior Passenger Cars and Trucks Many dealers and after-market repair shops advertise multi-point fluid "top-ups" in conjunction with oil changes or regular maintenance packages. These offers often include adding brake fluid to the master cylinder reservoir. There are only two reasons why the brake fluid level in the brake reservoir might go down. The first is that the brake fluid level goes down an acceptable level during normal brake lining wear. When the linings are replaced, the fluid will return to it's original level. The second possible reason for a low fluid level is that fluid is leaking out of the brake system. If fluid is leaking, the brake system requires repair and adding additional fluid will not correct the leak. If the system was properly filled during delivery of the vehicle, no additional fluid should be required under most circumstances between brake pad and/or shoe replacements. This information can be reinforced with the customer by referring them to the Brake Fluid section of their vehicle's Owner's Manual. Guidelines GM vehicles have incorporated a variety of brake fluid reservoir styles. The following guidelines are restricted to the plastic bodied fluid reservoirs and do not affect the original service recommendations for the older style metal bodied units. You may encounter both black plastic and translucent style reservoirs. You may have reservoirs with: ^ A MAX fill mark only ^ A MIN fill mark only ^ Both MAX and MIN marks The translucent style reservoirs do not have to have the covers removed in order to view the fluid level. It is a good practice not to remove the reservoir cover unless necessary to reduce the possibility of contaminating the system. Use the following guidelines to assist in determining the proper fluid level. Important: When adding brake fluid, use Delco Supreme II(R) Brake Fluid, GM P/N 12377967 or equivalent brand bearing the DOT-3 rating only. Important: At no time should the fluid level be allowed to remain in an overfilled condition. Overfilling the brake reservoir may put unnecessary stress on the seals and cover of the reservoir. Use the following guidelines to properly maintain the fluid level. If the reservoir is overfilled, siphon out the additional fluid to comply with the guidelines below. Important: If under any circumstance the brake fluid level is extremely low in the reservoir or the BRAKE warning indicator is illuminated, the brake system should be checked for leaks and the system repaired in addition to bringing the fluid level up to the recommended guidelines outlined below. A leaking brake system will have reduced braking performance and will eventually not work at all. Important: Some vehicles have reservoirs that are very sensitive to brake fluid levels and may cause the BRAKE indicator to flicker on turns as the fluid approaches the minimum required level. If you encounter a vehicle with this concern, increase the fluid level staying within the guidelines outlined below. ^ If the reservoir has a MAX level indicator, the reservoir should be returned to the MAX marking only at the time new brake pads and/or shoes are installed. If the reservoir fluid level is at the half-way point or above do not attempt to add additional brake fluid during routine fluid checks. ^ If the reservoir has both MAX and MIN indicators, the fluid level should be maintained above the MIN indicator during routine fluid checks and returned to the MAX indication only after new brake pads and/or shoes are installed. ^ For reservoirs with only a MIN indication, the fluid level should be maintained above the MIN indicator during routine fluid checks. Return the Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Brake Fluid - Level & Filling Recommendations > Page 8248 reservoir fluid level to full only after installing new brake pads and/or shoes. A full reservoir is indicated on translucent, snap cover reservoirs by a fluid level even with the top level of the view window imprinted into the side of the reservoir. On screw top models in black or translucent plastic, the full level is just below the bottom of the filler neck. Parts Information Part Number Description 12377967 Brake Fluid Parts are currently available from GMSPO. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 8249 Brake Fluid: Specifications Brake Fluid Type Delco Supreme II (R) Fluid, GM P/N 12377967 Or DOT-3 Equivalent Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 8253 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement (With ABS) Removal Procedure 1. Disconnect the electrical connector (2) from the fluid level sensor. 2. Remove the fluid level sensor. Use needle nose pliers in order to compress the switch locking tabs (1) at the side of the master cylinder. Installation Procedure 1. Install the fluid level sensor until the locking tabs snap into place. 2. Connect the electrical connector (2) to the fluid level sensor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Hose Brake Hose/Line: Specifications Hose Brake Hose Caliper Bolt 40 ft.lb Brake Hose Caliper Bolt 40 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Hose > Page 8258 Brake Hose/Line: Specifications Line Brake Pipe Fittings / Tube Nut 11 ft.lb Brake Pipe Tube Nut 11 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Hose Replacement - Front Brake Hose/Line: Service and Repair Brake Hose Replacement - Front Removal Procedure Caution: Do not move the vehicle until a firm brake pedal is obtained. Air in the brake system can cause loss of brakes with possible personal injury. Notice: Do not allow components to hang from the flexible brake hoses as damage to the hoses may occur. Some brake hoses have protective rings or covers to prevent direct contact of the hose with other chassis parts. Besides causing possible structural damage to the hose, excessive tension could cause the hose rings to move out of their proper locations. Notice: Brake hoses should not be crimped at any point, in order to prevent the loss of brake fluid from any component. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the front tire and the front wheel. Refer to Tire and Wheel Removal and Installation. 3. Clean the dirt and foreign material from the brake hoses and fitting. 4. Use a backup wrench on the hose fitting in order to remove the brake pipe from the brake hose at the bracket. Do not bend the brake pipe or the bracket. 5. Remove the retainer clip at the hose mounting bracket. 6. Remove the hose from the bracket. 7. Remove the following items from the caliper (2): ^ The brake hose bolt (4) ^ The hose (5) ^ The two washers (3) Discard the two washers. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Hose Replacement - Front > Page 8261 1. Install the following items to the caliper (2): ^ The brake hose bolt (4) ^ The hose (5) ^ The two new washers (3) Use two new washers. Notice: Refer to Fastener Notice in Service Precautions. 2. Lubricate the bolt threads with brake fluid. ^ Tighten the brake hose caliper bolt to 54 Nm (40 ft. lbs.). 3. Install the brake hose into the bracket. There should not be any kinks in the hose. Align the hose fitting with the notch in the bracket. Use the hose paint stripe as a visual aid. 4. Install the retainer clip onto the hose fitting at the bracket. 5. Connect the brake pipe to the brake hose: ^ Use a backup wrench on the hose fitting. ^ Do not bend the bracket or pipe. ^ Tighten the brake pipe tube nut to 15 Nm (11 ft. lbs.). 6. Install the front tire and the front wheel. Refer to Tire and Wheel Removal and Installation. 7. Ensure that the hose does not make contact with any part of the suspension. Check the hose in extreme right and extreme left turn conditions. If the hose makes contact, remove the hose and correct the condition. 8. Lower the vehicle. 9. Bleed the brakes. Refer to Hydraulic Brake System Bleeding. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Hose Replacement - Front > Page 8262 Brake Hose/Line: Service and Repair Brake Pipe Replacement (and ISO Flare Replacement) ^ Tools Required J 29803-A ISO Flaring Kit Caution: Always use double walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and cause brake system failure. Notice: Do not use single lap flaring tools. Double lap flaring tools must be used to produce a flare strong enough to hold the system pressure. Using single lap flaring tools could cause system damage. 1. Obtain the recommended tubing and steel fitting nuts of the correct size. Outside diameter tubing is used in order to specify the size. 2. Cut the tubing to length. In order to determine the correct length, measure the old pipe using a string and adding 3 mm (1/8 inch) for each ISO flare. 3. Before starting the flare, install the fittings on the tubing. 4. Chamfer the inside and outside diameter of the pipe with the de-burring tool. 5. Remove all traces of lubricant from the brake pipe and the flaring tool. 6. Clamp the flaring tool body in a vise. 7. Select the correct size collet and forming mandrel (3) for the pipe size used. 8. Insert the proper forming mandrel into the tool body. 9. While holding the mandrel in place with a finger, thread the forcing screw until the screw makes contact with the forming mandrel and begins to move the forming mandrel. 10. When contact is made with the forming mandrel, turn the forcing screw back one complete turn. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Hose Replacement - Front > Page 8263 11. Slide the clamping nut (1) over the brake pipe into the correct collet. Leave approximately 19 mm (3/4 inch) of tubing extending out the collet. 12. Insert the collet into the tool body. The brake pipe end must contact the face of the forming mandrel. 13. Tighten the clamping nut into the tool body very tight or the pipe may push out. 14. Wrench tighten the forcing screw until the screw bottoms. Do not over tighten the forcing screw or the flare may become over-sized. 15. Back the clamping nut out of the tool body. 16. Disassemble the clamping nut and collet. The flare is now ready for use. 17. Bend the pipe to match the old pipe. Maintain a clearance of 19 mm (3/4 inch) for all moving or vibrating components. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Hose Replacement - Front > Page 8264 Brake Hose/Line: Service and Repair Brake Hose Replacement - Rear Removal Procedure Caution: Do not move the vehicle until a firm brake pedal is obtained. Air in the brake system can cause loss of brakes with possible personal injury. Notice: Do not allow components to hang from the flexible brake hoses as damage to the hoses may occur. Some brake hoses have protective rings or covers to prevent direct contact of the hose with other chassis parts. Besides causing possible structural damage to the hose, excessive tension could cause the hose rings to move out of their proper locations. Notice: Brake hoses should not be crimped at any point to prevent loss of brake fluid from any component. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the rear tire and wheel. Refer to Tire and Wheel Removal and Installation. 3. Clean dirt and foreign material from the brake hoses and fittings. 4. Use a backup wrench on the hose fitting in order to remove the brake pipe from the brake hose (2) Do not bend the brake pipe or the bracket. 5. Remove the retainer clip from the brake hose at the bracket. 6. Remove the hose from the bracket. 7. Remove the following items from the caliper: ^ Brake hose bolt (1) ^ Brake hose (2) ^ Two sealing washers (4) Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Hose Replacement - Front > Page 8265 1. Install the brake hose bolt. Install the brake hose into the brackets. There should be no kinks in the hose. Align the hose fitting with a notch in the bracket. Use the hose paint stripe as a visual aid. ^ Tighten the Brake Hose bolt (1) to 54 Nm (40 ft. lbs.). 2. Use a backup wrench on the hose fitting in order to connect the brake pipe to the brake hose. 3. Do not bend the bracket or the pipe. ^ Tighten the tube nut to 15 Nm (11 ft. lbs.). 4. Install the retainer clips onto the hose fittings at the brackets. 5. Install the rear tire and wheel. Refer to Tire and Wheel Removal and Installation. 6. Lower the vehicle. 7. Bleed the brakes. Refer to Hydraulic Brake System Bleeding. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Component Specifications Brake Proportioning/Combination Valve: Specifications Proportioning Valve Tube Nuts 11 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Component Specifications > Page 8270 Brake Proportioning/Combination Valve: Specifications Proportioning Valve Caps 20 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > Proportioning Valve Replacement (With ABS) Brake Proportioning/Combination Valve: Service and Repair Proportioning Valve Replacement (With ABS) Removal Procedure Important: Do not wash the proportioning valve (1) in any cleaning solution. The internal components are pre-lubricated with a special grease. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Clean the dirt and foreign material from the brake pipes and proportioning valve (1). 3. Disconnect the brake pipe fittings from the proportioning valve (1) using a backup wrench. 4. Remove the proportioning valve. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > Proportioning Valve Replacement (With ABS) > Page 8273 1. Install the proportioning valve. Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the brake pipe fittings to the proportioning valve (1) using a backup wrench. ^ Tighten the Proportioning Valve Tube Nut to 15 Nm (11 ft. lbs.). 3. Lower vehicle. 4. Bleed the brakes. Refer to Hydraulic Brake System Bleeding. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > Proportioning Valve Replacement (With ABS) > Page 8274 Brake Proportioning/Combination Valve: Service and Repair Proportioning Valve Replacement (Non ABS) Removal Procedure Important: Do not wash the proportioning valve in any cleaning solution. The internal components are pre-lubricated with a special grease. 1. Remove the master cylinder reservoir. Refer to Master Cylinder Reservoir Replacement. 2. Remove the proportioning valve caps (1). 3. Remove the O-rings (5). 4. Remove the springs (2). 5. Remove the proportioning valve pistons (3). Carefully use needle nose pliers so that you do not damage the piston stems. 6. Remove the proportioning valve seals (4) from the pistons. 7. Inspect the proportioning valve pistons for corrosion and deformation. Replace the valve pistons if necessary. 8. Clean all of the parts in clean, denatured alcohol. 9. Dry the parts with non-lubricated compressed air. Installation Procedure 1. Lubricate the following parts with the silicone grease that is supplied in the repair kit: ^ O-rings (5) ^ Proportioning valve seals (4) ^ Proportioning valve piston stems (3) 2. Install new seals on the proportioning valve pistons. Ensure that the lip seals face up toward the cap. 3. Install the proportioning valve pistons and the seals in the master cylinder body. 4. Install the springs (2) in the master cylinder body. 5. Install new O-rings (5) in the grooves in the proportioning valve caps. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the proportioning valve caps (1) in the master cylinder body. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > Proportioning Valve Replacement (With ABS) > Page 8275 ^ Tighten the proportioning valve caps to 27 Nm (20 ft. lbs.). 7. Install the master cylinder reservoir. Refer to Master Cylinder Reservoir Replacement. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > Fastener Tightening Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Fastener Tightening Specifications Brake Pipe Fittings At Brake Pressure Modulator Valve (BPMV) And Master Cylinder ...................................................................................... 18 ft. lbs. Brake Pressure Modulator Valve (BPMV) and Electronic Brake Control Module (EBCM) Assembly to Mounting Bracket ............................ 89 inch lbs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > Fastener Tightening Specifications > Page 8280 Hydraulic Control Assembly - Antilock Brakes: Specifications Component Specifications Modulator Tube Nuts ........................................................................................................................... ................................................................... 11 ft. lbs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > Page 8281 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Modulator Bracket Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Modulator Bracket Replacement Removal Procedure 1. Turn the Ignition switch to the OFF position. 2. Remove the two BPMV mounting bracket nuts (3) and one bolt located near the bottom and one nut (1) located at the top of the BPMV mounting bracket (4) to the strut tower. 3. Disconnect the ground strap between the EBCM assembly and the chassis. 4. Remove the BPMV mounting bracket (4) from the vehicle. 5. Remove BPMV and EBCM assembly (2) from the BPMV mounting bracket (4). Installation Procedure 1. Install the BPMV and EBCM assembly (2) to the BPMV mounting bracket (4). 2. Install the BPMV bracket (4) to the strut tower. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the one bolt and three nuts that attach the BPMV mounting bracket (4) to the strut tower. ^ Tighten the lower two BPMV mounting bracket nuts (3) and bolt to 10 Nm (89 inch lbs.). ^ Tighten the top nut (1) for BPMV mounting bracket (4) to strut tower to 3 Nm (27 inch lbs.). 4. Reconnect the ground strap between the EBCM assembly and the chassis. 5. Turn the ignition switch to the RUN position, engine off. 6. Perform the A Diagnostic System Check - ABS. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Modulator Bracket Replacement > Page 8284 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Removal Procedure Caution: For safety reasons, the Brake Pressure Modulator Valve (BPMV) must not be repaired, the complete unit must be replaced With the exception of the EBCM/EBTCM, no screws may be loosened. if screws are loosened, it will not be possible to get the brake circuits leak-tight and personal injury may result. 1. Turn the ignition switch to the OFF position. 2. Remove the attaching bolts for the cruise control module. 3. Swing the cruise control module off to the side. 4. Disengage the red locking tab from the connector (1). 5. Push down lock tab (1) and then move sliding connector cover (2) to the open position. 6. Disconnect the EBCM harness connector. Important: Note the locations of the brake pipes in order to aid in installation. 7. Disconnect the brake pipes (1) from the BPMV (2). 8. Swing the four brakes pipes out of the way only after covering the open pipes to avoid dripping or being contaminated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Modulator Bracket Replacement > Page 8285 9. Disconnect the master cylinder brake pipes (2) from the BPMV (4). 10. It is not necessary to remove the brake pipes (2) from the master cylinder (1). 11. Swing the two master cylinder brake pipes out of the way only after covering the open pipes to avoid dripping or being contaminated. 12. Remove the two BPMV mounting bracket nuts (3) and one bolt located near the bottom and one nut (1) located at the top of the BPMV mounting bracket (4) to the strut tower. 13. Disconnect the ground strap between the EBCM assembly and the chassis. 14. Remove the BPMV mounting bracket (4) and EBCM assembly (2) from the vehicle. Notice: When removing the brake pressure modulator valve, protect the vehicle exterior from possible brake fluid spillage. Brake fluid can cause damage to painted surfaces. 15. Remove the four bolts (3) that connect the BPMV (1) to the mounting bracket (2). 16. Remove EBCM if replacing the BPMV only. Refer to Electronic Brake Control Module (EBCM) Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Modulator Bracket Replacement > Page 8286 Installation Procedure 1. Install EBCM onto the BPMV (1) if replacing the BPMV only. Refer to Electronic Brake Control Module (EBCM) Replacement. 2. Install BPMV and EBCM as an assembly (1) to the mounting bracket (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the four bolts (3) that connects the BPMV assembly (1) to the mounting bracket (2). ^ Tighten the four bolts (3) that connect the BPMV (1) to the mounting bracket (2) to 10 Nm (89 inch lbs.). 4. Install the BPMV bracket (4) to the strut tower. 5. Install the one bolt and three nuts that attach the BPMV Mounting bracket (4) to the strut tower. ^ Tighten the lower two BPMV mounting bracket nuts (3) and bolt to 10 Nm (84 inch lbs.). ^ Tighten the top nut (1) for BPMV mounting bracket (4) to strut tower to 3 Nm (27 inch lbs.). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Modulator Bracket Replacement > Page 8287 Important: If a new BPMV is being installed, remove the shipping plugs from the valve openings during the next few steps when ready. Caution: Make sure brake pipes are correctly connected to brake pressure modulator valve. If brake pipes are switched by mistake, wheel lockup will occur and personal injury may result. The only two ways this condition can be detected are by using a Scan Tool or by doing an Antilock stop. 6. Install the master cylinder brake pipes (2) into the BPMV (4). ^ Tighten the master cylinder brake pipe fittings to 24 Nm (18 ft. lbs.). 7. Install the brake pipes (1) on the BPMV (2). ^ Tighten all four brake pipe fittings to 24 Nm (18 ft. lbs.). 8. Reconnect the ground strap between the EBCM assembly and the chassis. 9. Connect the EBCM harness connector. 10. Push down lock tab (1) and then move sliding connector cover (2) back in home position to lock. 11. Insert red locking tab back in place. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Modulator Bracket Replacement > Page 8288 12. Reinstall the cruise control module. 13. When all procedures have been completed, the automated ABS bleed procedure is required. Refer to Automated Bleed Procedure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Fastener Tightening Specifications Brake Master Cylinder: Specifications Master Cylinder Mounting Nuts 18 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Fastener Tightening Specifications > Page 8293 Brake Master Cylinder: Specifications Master Cylinder Tube Nuts 18 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul Brake Master Cylinder: Service and Repair Master Cylinder Overhaul Removal Procedure Caution: Do not disturb or remove the screw which retains the primary spring to the secondary piston. This screw has been set to a predetermined height, and the performance of the master cylinder will be adversely affected if this setting is changed. An improperly adjusted screw may result in poor brake performance and possible personal injury. Important: The reservoir cap (1) and the diaphragm (3) may be inspected and serviced without removing the master cylinder from the vehicle. 1. Remove the master cylinder. Refer to Master Cylinder Replacement. 2. Wipe the reservoir cap (1) clean. 3. Remove the reservoir cap (1) and the diaphragm (3). 4. Replace the reservoir cap (1) and the diaphragm (3) if the following damage exists: ^ Cuts ^ Cracks ^ Nicks ^ Deformation 5. Remove the master cylinder reservoir. Refer to Master Cylinder Reservoir Replacement. 6. Remove the retainer (7) while depressing the primary piston (8). Use care so that you do not damage the following components: ^ The piston (8) ^ The bore ^ The retainer groove 7. Apply low pressure, non-lubricated, compressed air into the upper outlet port at the blind end of the bore while the other outlet ports are plugged. Perform the above action in order to remove the following components: 7.1. Primary piston (8) 7.2. Secondary piston (10) 7.3. Spring (13) 7.4. Spring retainer (12) 8. Remove the seals (9) and the spring retainer (12) from the secondary piston (10). 9. Inspect the master cylinder for scoring or corrosion. Replace the master cylinder if damage exists. Do not use abrasives in the bore. 10. Clean all of the components in clean, denatured alcohol. 11. Dry the components with non-lubricated, compressed air. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 8296 1. Install lubricated seals (9) and the spring retainer (12) onto the secondary piston. 2. Install the spring (13) and the secondary piston (10) into the cylinder bore. Lubricate the parts with clean brake fluid in order to ease assembly. 3. Install the lubricated primary piston (8) into the cylinder bore. 4. While depressing the primary position (8), install the retainer (7). 5. Install the master cylinder reservoir. Refer to Master Cylinder Reservoir Replacement. 6. Insert the diaphragm (3) into the reservoir cap (1), Install the cap (1) on the reservoir (4). 7. Install the master cylinder. Refer to Master Cylinder Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 8297 Brake Master Cylinder: Service and Repair Master Cylinder Replacement Removal Procedure 1. Remove the brake pipes from the master cylinder. 2. Disconnect fluid level sensor electrical connector (2). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 8298 3. Remove master cylinder mounting nuts (1). 4. Remove the master cylinder. 5. Drain the master cylinder reservoir of all brake fluid. 6. Remove the master cylinder reservoir. Refer to Master Cylinder Reservoir Replacement. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 8299 1. Install the master cylinder reservoir. Refer to Master Cylinder Reservoir Replacement. 2. Install the master cylinder. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the master cylinder mounting nuts (1). ^ Tighten the master cylinder mounting nuts (1) to 25 Nm (18 ft. lbs.). 4. Connect the fluid level sensor electrical connector (2). 5. Connect the brake pipes to the master cylinder. ^ Tighten the master cylinder tube nuts to 15 Nm (11 ft. lbs.). 6. Fill the master cylinder reservoir with brake fluid. Refer to Master Cylinder Reservoir Filling. 7. Bleed the brake system. Refer to Hydraulic Brake System Bleeding. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 8300 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement Removal Procedure Notice: Do not overtighten vise, or damage to the master cylinder will result. 1. Remove the master cylinder. Refer to Master Cylinder Replacement 2. Clamp the flange on the master cylinder body in a vise. Do not clamp the master cylinder body. 3. Carefully drive out the spring pins with a suitable 1/8 inch punch. Do not damage the reservoir or the cylinder body when pushing out the pins. 4. Remove the reservoir body by pulling the body straight up and away from the cylinder body. 5. Remove the O-rings (2) from the grooves in the reservoir. 6. Inspect the reservoir for cracks or deformation. Replace the reservoir if necessary. 7. Clean the reservoir with clean denatured alcohol. 8. Dry the reservoir with non-lubricated compressed air. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 8301 1. Lubricate the new O-rings and the reservoir-to-housing fittings with clean brake fluid. 2. Insert the O-rings into the grooves in the reservoir. Make sure that the O-rings are properly seated. 3. Connect the reservoir to the master cylinder body. Use your hand in order to press the reservoir straight down into the body. 4. Carefully install the spring pins in order to retain the reservoir. Do not damage the reservoir or the cylinder body. 5. Install master cylinder. Refer to Master Cylinder Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 8302 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Filling Caution: Do not overfill the brake fluid reservoir. Overfilling the brake fluid reservoir may cause the brake fluid to overflow onto the engine exhaust components during brake system service. The brake fluid is flammable and may cause a fire and personal injury if the brake fluid contacts the engine exhaust system components. The master cylinder reservoir is on the master cylinder. The reservoir is located under the hood on the left side of the vehicle. The master cylinder reservoir contains enough fluid so that the reservoir does not need service under normal conditions. A low fluid sensor in the master cylinder will warn of a low fluid level. ^ Clean the reservoir cap before removal in order to prevent dirt from entering the reservoir. ^ Remove the twist cap and the diaphragm. ^ Do not fill the reservoir past the maximum fill level. ^ When the reservoir is full, install the cap and the diaphragm. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator > Component Information > Service and Repair Parking Brake Actuator: Service and Repair Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation. 3. Remove the brake rotor. Refer to Brake Rotor Replacement (Front) or Brake Rotor Replacement (Rear). 4. Loosen the brake cables at the equalizer (2). 5. Remove the cable from the actuator lever. 6. Remove the parking brake return spring. 7. Remove the cable from the parking brake bracket (8). 8. Remove the rear wheel hub. Refer to Wheel Bearing/Hub Replacement - Rear. 9. Remove the parking brake bracket (8) from the support plate (7). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator > Component Information > Service and Repair > Page 8311 10. Remove the parking brake actuator (5). Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the parking brake bracket (8) through the support plate (7) and wheel hub into the parking brake actuator (5). ^ Tighten the parking brake bracket bolts to 10 Nm (89 inch lbs.). 2. Install the rear wheel hub. Refer to Wheel Bearing/Hub Replacement - Rear. 3. Install the parking brake return spring. 4. Install the cable onto the actuator lever. 5. Install the cable onto the parking brake bracket. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator > Component Information > Service and Repair > Page 8312 6. Tighten the nut on the equalizer (2) in order to remove the slack in the cable. 7. Install the brake rotor. Refer to Brake Rotor Replacement (Front) or Brake Rotor Replacement (Rear). 8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation. 9. Lower the vehicle. 10. Adjust the parking brake. Refer to Park Brake Cable Service/Adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Backing Plate > Component Information > Service and Repair Parking Brake Backing Plate: Service and Repair Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation. 3. Remove the brake caliper bracket. Refer to Brake Caliper Bracket Replacement (Front) or Brake Caliper Bracket Replacement (Rear) (Rear). 4. Loosen the brake cables at the equalizer (2). 5. Remove the cable from the actuator lever. 6. Remove the parking brake return spring. 7. Remove the cable from the parking brake bracket (8). 8. Remove the rear wheel hub. Refer to Wheel Bearing/Hub Replacement - Rear. 9. Remove the parking brake bracket (8) from the support plate (7) bolts. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Backing Plate > Component Information > Service and Repair > Page 8316 10. Remove the parking brake actuator (5). 11. Remove the parking brake shoe. Refer to Park Brake Shoe Replacement. 12. Remove the support plate (2). Installation Procedure 1. Install the parking brake support plate (7). 2. Install the parking brake shoe. Refer to Park Brake Shoe Replacement. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the parking brake bracket onto support plate (2). ^ Tighten the parking brake bracket bolts to 10 Nm (89 ft. lbs.). 4. Install the parking brake actuator (5). 5. Install the rear wheel hub. Refer to Wheel Bearing/Hub Replacement - Rear. 6. Install the parking brake return spring. 7. Install the cable onto the parking brake bracket. 8. Install the cable onto the actuator lever. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Backing Plate > Component Information > Service and Repair > Page 8317 9. Tighten the nut on the equalizer in order to remove the slack in the cable. 10. Install the brake rotor. Refer to Brake Rotor Replacement (Front) or Brake Rotor Replacement (Rear). 11. Install the brake caliper bracket. Refer to Brake Caliper Bracket Replacement (Front) or Brake Caliper Bracket Replacement (Rear) (Rear). 12. Install the brake caliper. Refer to Brake Caliper Replacement (Front) or Brake Caliper Replacement (Rear). 13. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation. 14. Lower the vehicle. 15. Adjust the parking brake. Refer to Park Brake Cable Service/Adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications Parking Brake Cable: Specifications Park Brake Cable Guide Mounting Bolt ............................................................................................... .................................................................. 18 ft. lbs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement (Front) Parking Brake Cable: Service and Repair Park Brake Cable Replacement (Front) Removal Procedure 1. Remove the left side instrument panel insulator. Refer to Insulator Replacement - IP (Left) in Instrument Panel, Gauges and Warning Indicators. 2. Remove the left side carpet retainers. Refer to Carpet Retainer Replacement (Impala) or Carpet Retainer Replacement (Monte Carlo). 3. Remove the lower center pillar trim panel on the left side. Refer to Trim Panel Replacement -Lower Center Pillar (Impala). 4. Fold back the carpeting in order to gain access to the parking brake cable. 5. Remove the parking brake cable from the park brake cable guides. 6. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 7. Remove the parking brake cable at the equalizer. 8. Lower the vehicle. 9. Remove the cable button end from the parking brake lever clevis. 10. Remove the front cable from the vehicle. Installation Procedure 1. Install the front cable into the vehicle. 2. Connect the cable to the parking brake lever. 3. Install the cable button in the lever clevis. 4. Install the cable button assurance clip to the lever clevis. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement (Front) > Page 8323 6. Tighten the nut on the equalizer (2) in order to remove the slack in the cable. 7. Lower the vehicle. 8. Install the parking brake cable through the park brake cable guides. 9. Position the carpeting properly. 10. Install the lower center pillar trim panel on the left side. Refer to Trim Panel Replacement Lower Center Pillar (Impala). 11. Install the left side carpet retainers. Refer to Carpet Retainer Replacement (Impala) or Carpet Retainer Replacement (Monte Carlo). 12. Install the left side instrument panel insulator. Refer to Insulator Replacement - IP (Left) in Instrument Panel, Gauges and Warning Indicators. 13. Adjust the parking brake. Refer to Park Brake Cable Service/Adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement (Front) > Page 8324 Parking Brake Cable: Service and Repair Park Brake Cable Replacement (Left/Right Rear) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Loosen the brake cable at the equalizer (2) and separate. 3. Remove the parking brake equalizer. 4. Remove the cable from the mounting bracket. 5. Remove the cable from the actuator lever. 6. Remove the parking brake cable from the vehicle. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement (Front) > Page 8325 1. Place the cable in position. 2. Install the cable on the actuator lever. 3. Install the cable on the mounting bracket. 4. Install the retaining pin. 5. Tighten the nut on the equalizer (2) in order to remove the slack in the cable. 6. Lower the vehicle. 7. Adjust the parking brake. Refer to Park Brake Cable Service/Adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement (Front) > Page 8326 Parking Brake Cable: Service and Repair Park Brake Cable Guide Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the cable guide mounting bolt. 3. Remove the cable guide (2). Installation Procedure 1. Install the cable guide (2). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the cable guide mounting bolt. ^ Tighten the cable guide mounting bolt to 25 Nm (18 ft. lbs.). 3. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement (Front) > Page 8327 Parking Brake Cable: Service and Repair Park Brake Cable Service/Adjustment 1. Adjust the rear brake shoe and lining. Refer to Park Brake Shoe Adjustment. 2. Apply and fully release the parking brake six times. 3. Verify that the parking brake pedal releases completely. ^ Turn ON the ignition. Verify that the BRAKE indicator lamp is off. ^ If the BRAKE indicator lamp is on, ensure that the parking brake pedal is in release mode and fully returned to stop. Remove the slack in the front parking brake cable by pulling downward on the cable. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Adjust the parking brake by turning the nut on the equalizer (2) while spinning both rear wheels. When either rear wheel starts to drag, back off the nut one full turn. 6. Lower the vehicle to curb height. Important: If the rear wheels rotate during the following test, adjust the parking brake shoe and lining. Refer to Park Brake Shoe Adjustment. 7. Apply the parking brake to four clicks. Inspect the rotation of the rear wheels: ^ The wheels should not rotate forward. ^ The wheels should drag or not rotate backward. 8. Release the parking brake. Verify that the wheels rotate freely. 9. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications Parking Brake Lever: Specifications Park Brake Lever Mounting Nuts 18 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair Parking Brake Pedal: Service and Repair Removal Procedure 1. Remove the driver's side instrument panel insulator. Refer to Insulator Replacement - IP (Left) or Insulator Replacement - IP (Right) in Instrument Panel, Gauges and Warning Indicators. 2. Remove the left carpet retainer. Refer to Carpet Retainer Replacement (Impala) or Carpet Retainer Replacement (Monte Carlo). 3. Pull back the carpet for access. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Loosen the nut on the parking brake equalizer (2). 6. Disconnect the front cable from the rear cable at the connector clip. 7. Remove the front cable from the connector clip. 8. Remove plastic pin in order to remove the front cable clip from the underbody bracket. 9. Lower the vehicle. 10. Disconnect the electrical connector at the parking brake switch (1). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Page 8334 11. Remove the three lever nuts from the body mounting studs. 12. Remove the parking brake pedal with the parking brake cable. 13. Remove the assurance clip from the cable button retainer clevis. 14. Remove the cable button end from the lever clevis. 15. Remove the parking brake switch, if being replaced. Installation Procedure 1. Install the parking brake switch, if removed. 2. Install the cable to the parking brake pedal. 3. Install the cable end to the lever clevis. 4. Install the assurance clip to the cable button retainer clevis 5. Install the parking brake pedal. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Page 8335 Notice: Refer to Fastener Notice in Service Precautions. 6. Install the parking brake pedal to body mounting nuts. ^ Tighten parking brake pedal mounting nuts to 25 Nm (18 ft. lbs.). 7. Connect the electrical connector at the parking brake switch. 8. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 9. Feed the cable through the underbody and clip the cable into the under body bracket. 10. Install the front cable into the connector clip (2). 11. Tighten the parking brake cable at the equalizer. 12. Lower the vehicle. 13. Position the carpet in place. 14. Install the left carpet retainer. Refer to Carpet Retainer Replacement (impala) or Carpet Retainer Replacement (Monte Carlo). 15. Install the driver's side insulator panel. Refer to Insulator Replacement - IP (Left) or Insulator Replacement - IP (Right) in Instrument Panel, Gauges and Warning Indicators. 16. Adjust the parking brake. Refer to Park Brake Cable Service/Adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Locations > Component Locations > Page 8340 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments Parking Brake Shoe: Adjustments ^ Tools Required J 21177-A Drum-to-Brake Shoe Clearance Gage 1. Remove the brake caliper bracket. Refer to Brake Caliper Bracket Replacement (Front) or Brake Caliper Bracket Replacement (Rear). 2. Loosen the adjusting nut on the parking brake cable until the lever is at the rest position. 3. Remove the rotor. Turn the rotor slowly while pulling the rotor away from the hub. 4. Set the J 21177-A so that the J 21177-A contacts the inside diameter of the rotor (1). 5. Position the J 21177-A over the shoe and lining at the widest point. 6. Turn the adjuster nut until the shoe and lining (1) just contacts the J 21177-A. 7. Repeat steps two through five for the rotor on the opposite side. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 8344 8. Adjust the adjusting nut on the rear parking brake cable. Refer to Park Brake Cable Service/Adjustment. 9. Install the rotor. Turn the rotor slowly while sliding the rotor onto the bearing assembly. 10. Tighten the parking brake cable adjusting nut. Refer to Park Brake Cable Service/Adjustment. 11. Install the brake caliper bracket. Refer to Brake Caliper Bracket Replacement (Front) or Brake Caliper Bracket Replacement (Rear). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 8345 Parking Brake Shoe: Service and Repair Removal Procedure 1. Remove the caliper bracket. Refer to Brake Caliper Bracket Replacement (Front) or Brake Caliper Bracket Replacement (Rear). 2. Remove the rotor. Refer to Brake Rotor Replacement (Front) or Brake Rotor Replacement (Rear). 3. Remove the rear wheel hub. Refer to Wheel Bearing/Hub Replacement - Rear. 4. Remove the parking brake actuator (5). Refer to Park Brake Actuator Replacement 5. Remove the park brake shoe. Installation Procedure Important: Ensure that the park brake shoe (1) engages the Park brake actuator. 1. Install shoe and lining. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 8346 2. Install the rear wheel hub. Refer to Wheel Bearing/Hub Replacement - Rear. 3. Install the parking brake actuator. Refer to Park Brake Actuator Replacement. 4. Install the rear wheel hub. Refer to Wheel Bearing/Hub Replacement - Rear. 5. Adjust the rear parking brake shoe. Refer to Park Brake Cable Service/Adjustment. 6. Install the rotor. Refer to Brake Rotor Replacement (Front) or Brake Rotor Replacement (Rear). 7. Install the caliper bracket. Refer to Brake Caliper Bracket Replacement (Front) or Brake Caliper Bracket Replacement (Rear). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Specifications Parking Brake Warning Switch: Specifications Park Brake Indicator Switch Mounting Screw ..................................................................................................................................................... 26 inch lbs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Specifications > Page 8350 Parking Brake Warning Switch: Service and Repair Removal Procedure 1. Remove the left side instrument panel insulator. Refer to Insulator Replacement - IP (Left) in Instrument Panel, Gauges and Warning Indicators. 2. Remove the left carpet retainer and pull carpet back. Refer to Carpet Retainer Replacement (Impala) or Carpet Retainer Replacement (Monte Carlo) 3. Disconnect the electrical connector from the switch. 4. Remove the mounting screw. 5. Remove the parking brake indicator switch (1). Installation Procedure 1. Install the parking brake indicator switch (1). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the mounting screw. ^ Tighten the mounting screw to 3 Nm (26 inch lbs.). 3. Connect the electrical connector to the switch. Check the operation of the switch. 4. Install the left carpet retainer and carpet. Refer to Carpet Retainer Replacement (Impala) or Carpet Retainer Replacement (Monte Carlo). 5. Install the left side instrument panel insulator. Refer to Insulator Replacement - IP (Left) in Instrument Panel, Gauges and Warning Indicators. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications J-22805-01 To Brake Booster Attaching Nuts 18 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Vacuum Brake Booster Replacement Vacuum Brake Booster: Service and Repair Vacuum Brake Booster Replacement Removal Procedure Caution: When replacing the power booster brake, make sure that the cruise control cable is not routed between the booster and the cowl. If the cable is damaged or pinched, it must be replaced. Failure to do this could result in personal injury. Notice: Inspect the locking flanges on booster and mounting plate. Replace the booster and mounting plate if the locking flanges are bent or damaged. ^ Tools Required J 22805-01 Power Brake Booster Holder 1. Remove the fuel injector sight shield (3.8 Liter engine only). Important: It is not necessary to undo brake lines from the master cylinder or (If equipped with ABS) the brake modulator. 2. (If equipped with ABS) Remove the Brake modulator. Refer to Brake Pressure Modulator Valve (BPMV) Replacement and remove the master cylinder. Refer to Master Cylinder Replacement. 3. Remove the transmission fluid filler tube. Refer to Fluid Filler Tube Replacement. 4. Remove the EGR heat shield. Notice: When disconnecting the pushrod from the brake pedal, the brake pedal must be held stationary or damage to the brake switch may result. 5. Remove the brake booster pushrod from the brake pedal. Refer to Brake Pedal Replacement. 6. Remove the vacuum hose (2) from the brake booster vacuum check valve (1). Notice: Refer to Fastener Notice in Service Precautions. 7. Attach the J 22805-01 to the booster (2) using the master cylinder nuts. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Vacuum Brake Booster Replacement > Page 8357 ^ Tighten the master cylinder nuts to 25 Nm (18 ft. lbs.). 8. Unlock the booster from the front of the dash. 9. Use a flat bladed tool (4) in order to pry the locking tab (5) on the booster out of the locking notch (3) on the mounting flange. Do this while turning the booster counterclockwise with a wrench (1) on the J 22805-01. Notice: Do not attempt to remove the booster until pushrod is disconnected from the brake pedal. Important: Do not damage the insulator boot mounted on the front of the dash when pulling the pushrod eye through the hole. 10. Remove the booster. Installation Procedure Notice: Internal components of this booster are not serviceable. The housing must not be unstaked and separated. Separating the housing will cause permanent deformation, preventing the booster from holding proper volume. Notice: Refer to Fastener Notice in Service Precautions. 1. Attach the J 22805-01 to the new booster using the master cylinder nuts. ^ Tighten the master cylinder nuts to 25 Nm (18 ft. lbs.). Important: Carefully push the pushrod (1) eye through the hole so that you do not damage or dislodge the insulator boot. 2. Place the booster on the cowl counterclockwise from the final installation position so that the locking flanges on the booster and on the mounting engage. Important: Ensure that the locking tab and the flanges are in the fully engaged position. 3. Turn the booster clockwise (3) with the wrench on the J 22805-01. Do not use a screwdriver in the locking tab in order to install the booster. When the booster is correctly installed, the locking tab slides up the flange and snaps in the locking notch. 4. Connect the brake booster pushrod to the brake pedal. Refer to Brake Pedal Replacement. 5. Connect the vacuum hose (2) to the brake booster vacuum check valve (1). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Vacuum Brake Booster Replacement > Page 8358 6. Install the transmission fluid filler tube. Refer to Fluid Filler Tube Replacement. 7. Install the EGR heat shield. 8. (If equipped with ABS) Install the brake modulator. Refer to Brake Pressure Modulator Valve (BPMV) Replacement and Install the master cylinder. Refer to Master Cylinder Replacement. 9. Install the fuel injector sight shield (3.8 Liter engine only). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Vacuum Brake Booster Replacement > Page 8359 Vacuum Brake Booster: Service and Repair Vacuum Brake Booster Hose Replacement Removal Procedure 1. Disconnect the vacuum hose (2) from the vacuum brake booster check valve (1). 2. Remove the fuel injector sight shield. 3. Disconnect the vacuum hose from the intake manifold. Installation Procedure 1. Connect the vacuum hose to the intake manifold. 2. Install the fuel injector sight shield. 3. Connect the vacuum hose (2) to vacuum brake booster (1). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Service and Repair Vacuum Brake Booster Check Valve: Service and Repair Removal Procedure Important: The vacuum check valve and the grommet may be inspected and serviced without removing the booster from the vehicle. 1. Disconnect the brake booster vacuum hose (2) at the vacuum check valve (1). 2. Disconnect the brake booster vacuum check valve (2) from the booster (5). Installation Procedure 1. Connect the brake booster vacuum check valve (2) to the booster (5). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Service and Repair > Page 8363 2. Connect the brake booster vacuum hose (2) at the vacuum check valve (1). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON Electronic Brake Control Module: Customer Interest Tire Inflation Monitor - False Message/Lamp ON File In Section: 03 - Suspension Bulletin No.: 01-03-10-008A Date: February, 2002 TECHNICAL Subject: False Tire Inflation Monitor System (TIM) Message/Lamp Illumination (Install New Electronic Brake Traction Control Module - EBTCM) Models: 1999-2001 Buick Century, Regal This bulletin is being revised to add additional Existing ECU Part Numbers. Please discard Corporate Bulletin Number 01-03-1-008 (Section 03-Suspension) Condition Some owners may comment on the "Low Tire Pressure" message appearing or illumination of the "Low Tire" lamp. After checking the vehicle tire pressures, owners have indicated that none of the tires were found to be under inflated 12 psi (53 kPa) or more in comparison to the other three assemblies. This condition typically can be duplicated by operating the vehicle over a rough washboard type road surface. Correction Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON > Page 8373 Replace the existing EBCM/EBTCM with a new component selected from the following table. To determine the correct part number to order, locate the ECU PN (1) as shown in figure, on the existing EBCM/EBTCM label. Then refer to the chart to determine the correct service part number. Follow the applicable SI 2000 service procedure indicated by vehicle year and model. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON Electronic Brake Control Module: All Technical Service Bulletins Tire Inflation Monitor - False Message/Lamp ON File In Section: 03 - Suspension Bulletin No.: 01-03-10-008A Date: February, 2002 TECHNICAL Subject: False Tire Inflation Monitor System (TIM) Message/Lamp Illumination (Install New Electronic Brake Traction Control Module - EBTCM) Models: 1999-2001 Buick Century, Regal This bulletin is being revised to add additional Existing ECU Part Numbers. Please discard Corporate Bulletin Number 01-03-1-008 (Section 03-Suspension) Condition Some owners may comment on the "Low Tire Pressure" message appearing or illumination of the "Low Tire" lamp. After checking the vehicle tire pressures, owners have indicated that none of the tires were found to be under inflated 12 psi (53 kPa) or more in comparison to the other three assemblies. This condition typically can be duplicated by operating the vehicle over a rough washboard type road surface. Correction Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON > Page 8379 Replace the existing EBCM/EBTCM with a new component selected from the following table. To determine the correct part number to order, locate the ECU PN (1) as shown in figure, on the existing EBCM/EBTCM label. Then refer to the chart to determine the correct service part number. Follow the applicable SI 2000 service procedure indicated by vehicle year and model. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 8380 Electronic Brake Control Module: Specifications Brake Pressure Modulator Valve (BPMV) and Electronic Brake Control Module (EBCM) Assembly to Mounting Bracket 89 in.lb Electronic Brake Control Module (EBCM) to Brake Pressure Modulator Valve (BPMV) 44 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Component Locations > Page 8383 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Electronic Brake Traction Control Module (EBTCM), C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Electronic Brake Traction Control Module (EBTCM), C1 > Page 8386 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 8387 Electronic Brake Control Module: Service and Repair Removal Procedure Notice: To prevent equipment damage, never connect or disconnect the wiring harness connection from the EBCM with the ignition switch in the ON position. 1. Turn the ignition switch to the OFF position. 2. Remove red locking tab from connector lock tab (1). 3. Push down lock tab (1) and then move sliding connector cover (2) to the open position. 4. Disconnect the EBCM harness connector. 5. Brush off any dirt/debris that has accumulated on the assembly. 6. Remove the four EBCM to BPMV screws (1). 7. Separate the EBCM (2) from the BPMV (3) by gently pulling apart until separated. Important: Do not pry apart using a tool. Be careful not to damage BPMV surface. Important: Care must be taken not to damage the solenoid valves when the EBCM is removed from the BPMV. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 8388 1. Clean the BPMV surface with alcohol using a clean rag. 2. Install the EBCM (2) to the BPMV (3). 3. Install the four screws (1) that attaches the EBCM (2) to BPMV (3). Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the four screws to 5 Nm (44 inch lbs.). 4. Connect the EBCM harness connector. 5. Push down lock tab (1) and then move sliding connector cover (2) back in the home position to lock. 6. Insert red locking tab back in place. 7. Turn the ignition switch to the RUN position, do not start engine. 8. Perform the A Diagnostic System Check - ABS. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > Customer Interest for Traction Control Module: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON Traction Control Module: Customer Interest Tire Inflation Monitor - False Message/Lamp ON File In Section: 03 - Suspension Bulletin No.: 01-03-10-008A Date: February, 2002 TECHNICAL Subject: False Tire Inflation Monitor System (TIM) Message/Lamp Illumination (Install New Electronic Brake Traction Control Module - EBTCM) Models: 1999-2001 Buick Century, Regal This bulletin is being revised to add additional Existing ECU Part Numbers. Please discard Corporate Bulletin Number 01-03-1-008 (Section 03-Suspension) Condition Some owners may comment on the "Low Tire Pressure" message appearing or illumination of the "Low Tire" lamp. After checking the vehicle tire pressures, owners have indicated that none of the tires were found to be under inflated 12 psi (53 kPa) or more in comparison to the other three assemblies. This condition typically can be duplicated by operating the vehicle over a rough washboard type road surface. Correction Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > Customer Interest for Traction Control Module: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON > Page 8397 Replace the existing EBCM/EBTCM with a new component selected from the following table. To determine the correct part number to order, locate the ECU PN (1) as shown in figure, on the existing EBCM/EBTCM label. Then refer to the chart to determine the correct service part number. Follow the applicable SI 2000 service procedure indicated by vehicle year and model. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Control Module: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON Traction Control Module: All Technical Service Bulletins Tire Inflation Monitor - False Message/Lamp ON File In Section: 03 - Suspension Bulletin No.: 01-03-10-008A Date: February, 2002 TECHNICAL Subject: False Tire Inflation Monitor System (TIM) Message/Lamp Illumination (Install New Electronic Brake Traction Control Module - EBTCM) Models: 1999-2001 Buick Century, Regal This bulletin is being revised to add additional Existing ECU Part Numbers. Please discard Corporate Bulletin Number 01-03-1-008 (Section 03-Suspension) Condition Some owners may comment on the "Low Tire Pressure" message appearing or illumination of the "Low Tire" lamp. After checking the vehicle tire pressures, owners have indicated that none of the tires were found to be under inflated 12 psi (53 kPa) or more in comparison to the other three assemblies. This condition typically can be duplicated by operating the vehicle over a rough washboard type road surface. Correction Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Control Module: > 01-03-10-008A > Feb > 02 > Tire Inflation Monitor - False Message/Lamp ON > Page 8403 Replace the existing EBCM/EBTCM with a new component selected from the following table. To determine the correct part number to order, locate the ECU PN (1) as shown in figure, on the existing EBCM/EBTCM label. Then refer to the chart to determine the correct service part number. Follow the applicable SI 2000 service procedure indicated by vehicle year and model. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 8408 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement (With ABS) Removal Procedure 1. Disconnect the electrical connector (2) from the fluid level sensor. 2. Remove the fluid level sensor. Use needle nose pliers in order to compress the switch locking tabs (1) at the side of the master cylinder. Installation Procedure 1. Install the fluid level sensor until the locking tabs snap into place. 2. Connect the electrical connector (2) to the fluid level sensor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Component Locations > Page 8413 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Specifications Parking Brake Warning Switch: Specifications Park Brake Indicator Switch Mounting Screw ..................................................................................................................................................... 26 inch lbs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Specifications > Page 8417 Parking Brake Warning Switch: Service and Repair Removal Procedure 1. Remove the left side instrument panel insulator. Refer to Insulator Replacement - IP (Left) in Instrument Panel, Gauges and Warning Indicators. 2. Remove the left carpet retainer and pull carpet back. Refer to Carpet Retainer Replacement (Impala) or Carpet Retainer Replacement (Monte Carlo) 3. Disconnect the electrical connector from the switch. 4. Remove the mounting screw. 5. Remove the parking brake indicator switch (1). Installation Procedure 1. Install the parking brake indicator switch (1). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the mounting screw. ^ Tighten the mounting screw to 3 Nm (26 inch lbs.). 3. Connect the electrical connector to the switch. Check the operation of the switch. 4. Install the left carpet retainer and carpet. Refer to Carpet Retainer Replacement (Impala) or Carpet Retainer Replacement (Monte Carlo). 5. Install the left side instrument panel insulator. Refer to Insulator Replacement - IP (Left) in Instrument Panel, Gauges and Warning Indicators. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Component Locations Traction Control Switch: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Component Locations > Page 8422 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Component Locations > Page 8423 Traction Control Switch: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Component Locations > Page 8424 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Component Locations > Page 8425 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 8426 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 8427 Traction Control Switch: Service and Repair REMOVAL PROCEDURE 1. Apply the parking brake, if equipped with column shift. 2. Position the transaxle shift control indicator to 1, if equipped with column shift. 3. Adjust the steering wheel for access. 4. Remove the ignition switch cylinder bezel. 5. Remove the LH instrument panel (IP) fuse block access opening cover. 6. Remove the LH P cluster trim plate screws. 7. Start at the left side of the P cluster trim plate. Grasp the trim plate and carefully pull rearward. Disengage enough IP cluster trim plate retainers in order to easily access the traction control switch. 8. Disconnect the electrical connectors from the traction control switch. 9. Remove the traction control switch from the IP cluster trim plate. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 8428 1. Install the traction control switch to the IP cluster trim plate. 2. Connect the electrical connector to the traction control switch. 3. Carefully press the IP cluster trim plate into the IP trim pad. Make sure all of the retainers are fully engaged. 4. Install the LH IP cluster trim plate screws. Tighten Tighten the IF cluster trim plate screws to 2 N.m (18 lb in). 5. Install the LH instrument panel (IP) fuse block access opening covers. 6. Install the ignition switch cylinder bezel. 7. Return the steering wheel to the original position. 8. Position the transaxle shift control indicator to Park, if equipped with a column shift. 9. Push to release the parking brake, if equipped with column shift. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > LF Wheel Speed Sensor Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > LF Wheel Speed Sensor > Page 8433 Wheel Speed Sensor: Locations Wheel Speed Sensor, Rear In the rear wheel hub(s). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, LF Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, LF > Page 8436 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, LF > Page 8437 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, LF > Page 8438 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (Front) Removal Procedure Important: The front wheel speed sensors and rings are integral with the hub and bearing assemblies. If a speed sensor or a ring needs replacement, replace the entire hub and bearing assembly. Do not service the harness pigtail individually because the harness pigtail is part of the sensor. Refer to Front Wheel Drive Shaft Bearing Replacement. 1. Raise and support the vehicle on a suitable hoist. Refer to Vehicle Lifting. 2. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation. 3. Remove the front wheel speed sensor jumper harness electrical connector (1) from the front wheel speed sensor connector (3). 4. Remove the hub and bearing assembly (2). Refer to Front Wheel Drive Shaft Bearing Replacement for removal. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) > Page 8441 1. Install the hub and bearing assembly (2) to the vehicle. Refer to Front Wheel Drive Shaft Bearing Replacement for installation. 2. Install the front wheel speed sensor jumper harness electrical connector (1) to front wheel speed sensor connector (3). 3. Install the wheel and tire assembly. Refer to Tire and Wheel Removal and Installation. 4. Lower the vehicle. 5. Turn the ignition switch to the RUN position with the engine off. 6. Perform the A Diagnostic System Check - ABS. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) > Page 8442 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (Rear) Removal Procedure Important: The rear wheel speed sensors and rings are integral with the hub and bearing assemblies. If a speed sensor or a ring needs replacement, replace the entire hub and bearing assembly. Refer to Wheel Bearing/Hub Replacement - Rear. 1. Raise and support the vehicle on a suitable hoist. Refer to Vehicle Lifting. 2. Remove the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation. 3. Remove the rear wheel speed sensor electrical connector (1) located next to the rear strut (2). 4. Remove the hub and bearing assembly (1). Refer to Wheel Bearing/Hub Replacement - Rear for removal. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) > Page 8443 1. Install the hub and bearing assembly (1) to the vehicle. Refer to Wheel Bearing/Hub Replacement - Rear for installation. 2. Install the rear wheel speed sensor electrical connector (1). 3. Install the wheel and tire assembly. Refer to Tire and Wheel Removal and Installation. 4. Lower the vehicle. 5. Turn the ignition switch to the RUN position with the engine off. 6. Perform the A Diagnostic System Check ABS. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Switch Lock Cylinder - Dash Mounted Ignition Switch Lock Cylinder: Service and Repair Ignition Switch Lock Cylinder - Dash Mounted IGNITION SWITCH LOCK CYLINDER REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the body control module (BCM) theft deterrent relearn procedure whenever you replace the ignition switch lock cylinder. See: Body and Frame/Body Control Systems/Body Control Module/Service and Repair/Procedures/Body Control Module (BCM) Programming/RPO Configuration 1. Disconnect the negative battery cable. 2. Remove the instrument panel (I/P) cluster trim plate. 3. Insert the key and turn the ignition lock cylinder to the ON/RUN position. 4. Using a small curved tool or an L-shaped hex wrench, depress and hold the detent on the ignition lock cylinder. Access the detent by placing the tool through the I/P opening to the right of the ignition switch. If you cannot locate the detent with the tool, lower the ignition switch away from the I/P. Refer to Ignition Switch Replacement. 5. Using the key as an aid, pull to remove the lock cylinder from the switch. 6. Remove the key from the lock cylinder. 7. If the cylinder does not rotate or is seized, follow the procedure in the ignition switch replacement. Refer to Ignition Switch Replacement. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Switch Lock Cylinder - Dash Mounted > Page 8451 1. Code the ignition lock cylinder, if necessary. Refer to Key and Lock Cylinder Coding. 2. Insert the key and turn the lock cylinder to the ON/RUN position. 3. Position the lock cylinder to the ignition switch. Press the cylinder into place. If you turned the key slightly while removing the lock cylinder, you may have to align the white colored ignition switch rotor (1) with the lock cylinder (2). You can rotate the ignition switch rotor (1) with your finger. 4. Turn the key to the OFF position and remove the key. 5. Install the I/P cluster trim plate. 6. Connect the negative battery cable. 7. If you installed a new lock cylinder, perform the BCM theft deterrent relearn procedure. See: Body and Frame/Body Control Systems/Body Control Module/Service and Repair/Procedures/Body Control Module (BCM) Programming/RPO Configuration Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Switch Lock Cylinder - Dash Mounted > Page 8452 Ignition Switch Lock Cylinder: Service and Repair Programming/Learn Procedures Programming Replacement Lock Cylinder, BCM or PCM IMPORTANT: Reprogram the body control module (BCM) with the proper RPO configurations before you perform the learn procedures. When you replace the BCM, the module will learn Passlock Sensor Data Code immediately. However, the existing PCM must learn the new fuel continue password. When you replace a PCM, after programming, these modules will learn the incoming fuel continue password immediately upon receipt of a password message. Once a password message is received, and a password is learned, perform the learn procedure again if you want to change this password. A PCM which was previously installed in another vehicle will have learned the other vehicle's fuel continue password, and will require a learn procedure after programming in order to learn the current vehicle's password. 10 Minute Re-Learn Procedure Use this procedure after replacing any of the following components: 1. Lock Cylinders/Passlock Sensors 2. BCM 3. PCM Tech 2 Programming Procedure Use the following procedures in order to program the BCM with the Tech 2 equipment. 1. Connect the Tech 2 Diagnostic tool. 2. Select Request Information under Service Programming. 3. Disconnect the Tech 2 from the vehicle and connect it to a Techline Terminal. 4. On the Techline Terminal, select Theft Module Re-Learn under Service Programming. 5. Disconnect the Tech 2 from the Techline Terminal and connect the Tech 2 to the vehicle. 6. Turn ON the ignition, with the engine OFF. 7. Select VTD Re-Learn under Service Programming. 8. At this point you may disconnect the Tech 2, the Tech 2 is no longer required. 9. Observe the Security telltale, after approximately 10 minutes the telltale will turn OFF. The vehicle is now ready to relearn the Passlock Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. 10. Turn OFF the ignition, and wait 5 seconds. 11. Start the engine. (The vehicle has now learned keys). 12. Using a scan tool, clear any DTCs. 30 Minute Re-Learn Procedure Use this procedure after replacing lock cylinders, Passlock Module/BCM or the PCM (if necessary - see note above). 1. Turn ON the ignition, with the engine OFF. 2. Attempt to start the engine, then release the key to ON (The vehicle will not start). 3. Observe the Security telltale, after approximately 10 minutes the telltale will turn OFF. 4. Turn OFF the ignition, and wait 5 seconds. 5. Repeat steps 1-4 two more times, for a total of 3 cycles and 30 minutes. The vehicle is now ready to relearn the Passlock Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. IMPORTANT: The vehicle learns the Passlock Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. You must turn the ignition OFF before attempting to start the vehicle. 6. Start the engine. (The vehicle has now learned the Passlock Sensor Data Code and/or password.) 7. Using a scan tool, clear any DTCs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions > Technician Safety Information Jump Starting: Technician Safety Information CAUTION: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions: - Air bag deployment - Personal injury - Unnecessary SIR system repairs In order to avoid the above conditions, observe the following guidelines: - Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring. - If you are performing service on or near the SIR components or the SIR wiring, disable the SIR system. Refer to Disabling the SIR System in SIR. CAUTION: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components. CAUTION: Batteries produce explosive gases, contain corrosive acid, and supply levels of electrical current high enough to cause burns. Therefore, to reduce the risk of personal injury when working near a battery: - Always shield your eyes and avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow the battery electrolyte to contact the eyes or the skin. Flush immediately and thoroughly any contacted areas with water and get medical help. - Follow each step of the jump starting procedure in order. - Treat both the booster and the discharged batteries carefully when using the jumper cables. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions > Technician Safety Information > Page 8458 Jump Starting: Vehicle Damage Warnings NOTE: Never operate the starter motor for more than 30 seconds at a time. Allow it to cool for at least two minutes. Overheating, caused by too much cranking, will damage the starter motor. NOTE: Do not use the boost, jump start, crank, or an equivalent setting that may be available on the battery charger for prolonged charging of the battery. Using such settings may damage the battery due to overheating, excessive gassing, or spewing of electrolyte from the vents. NOTE: This vehicle has a 12 Volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 Volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions > Page 8459 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels at electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 Volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 Volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. 1. Position the vehicle with the booster (charged) battery so that the jumper cables will comfortably reach. - Do not let the two vehicles touch. - Make sure that the jumper cables do not have loose clamps, or missing insulation. 2. Place the automatic transmission in PARK. 3. Set the parking brake. 4. Block the wheels. 5. Turn off all electrical loads that are not needed (leave the hazard flashers ON). 6. Turn OFF the ignition switch. 7. Attach the end of one jumper cable to the positive terminal of the booster battery (A1). 8. Open the junction block cover. 9. Attach the other end of the same jumper cable to the junction block terminal (B2). 10. Attach one end of the remaining jumper cable to the negative terminal of the booster battery (A3). NOTE: Do not connect the negative booster cable to the housings of other vehicle electrical accessories or equipment. The current flow during jump starting may damage such equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions > Page 8460 11. Make the final connection of the negative cable to the grounding tab on the generator mounting bracket, connected directly to the block, away from the discharged battery (B4). 12. Start the engine of the vehicle that is providing the jump start and turn off all electrical accessories. 13. Crank the engine of the vehicle with the discharged battery. 14. Reverse the steps exactly when removing the jumper cables. The negative battery cable must first be disconnected from the engine that was jump started. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service Precautions > Technician Safety Information Negative: Technician Safety Information CAUTION: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions: - Air bag deployment - Personal injury - Unnecessary SIR system repairs In order to avoid the above conditions, observe the following guidelines: - Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring. - If you are performing service on or near the SIR components or the SIR wiring, disable the SIR system. Refer to Disabling the SIR System in SIR. CAUTION: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components. CAUTION: Batteries produce explosive gases, contain corrosive acid, and supply levels of electrical current high enough to cause burns. Therefore, to reduce the risk of personal injury when working near a battery: - Always shield your eyes and avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow the battery electrolyte to contact the eyes or the skin. Flush immediately and thoroughly any contacted areas with water and get medical help. - Follow each step of the jump starting procedure in order. - Treat both the booster and the discharged batteries carefully when using the jumper cables. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service Precautions > Technician Safety Information > Page 8466 Negative: Vehicle Damage Warnings NOTE: Never operate the starter motor for more than 30 seconds at a time. Allow it to cool for at least two minutes. Overheating, caused by too much cranking, will damage the starter motor. NOTE: Do not use the boost, jump start, crank, or an equivalent setting that may be available on the battery charger for prolonged charging of the battery. Using such settings may damage the battery due to overheating, excessive gassing, or spewing of electrolyte from the vents. NOTE: This vehicle has a 12 Volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 Volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Negative) Negative: Service and Repair Battery Cable Replacement (Negative) REMOVAL PROCEDURE IMPORTANT: When replacing battery cables be sure to use replacement cables that are the same type, gauge and length. 1. Disconnect the battery negative cable from the battery. 2. Remove the battery negative cable bolt and the battery ground negative cable from the frame rail near the underhood accessory wiring junction block. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 4. Remove the transaxle stud nut (3) and disconnect the battery ground negative cable (4) from the transaxle stud. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Negative) > Page 8469 5. Remove the battery cable retainers (2,3,4) from the frame. 6. Remove the battery ground negative cable from the wiring harness conduit. INSTALLATION PROCEDURE 1. Install the battery ground negative cable into the wiring harness conduit. 2. Install the battery cable retainers (2,3,4) to the frame. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the battery ground negative cable (4) and the transaxle stud nut (3) to the transaxle stud. Tighten Tighten the transaxle stud nut (3) to 25 N.m (18 lb ft). 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Negative) > Page 8470 5. Connect the battery ground negative cable and the battery negative cable bolt to the frame rail near the underhood accessory wiring junction block. Tighten Tighten the battery negative cable bolt to 8 N.m (71 lb in). 6. Connect the battery negative cable to the battery. Tighten Tighten the battery negative cable terminal bolt to 15 N.m (11 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Negative) > Page 8471 Negative: Service and Repair Battery Negative Cable Disconnect/Connect Procedure REMOVAL PROCEDURE CAUTION: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions: - Air bag deployment - Personal injury - Unnecessary SIR system repairs In order to avoid the above conditions, observe the following guidelines: - Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring. - If you are performing service on or near the SIR components or the SIR wiring, disable the SIR system. Refer to Disabling the SIR System in SIR. CAUTION: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components. 1. Record all of the vehicle preset radio stations. 2. Turn OFF all the lamps and the accessories. 3. Make sure the ignition switch is in the OFF position. 4. Disconnect the battery negative cable from the battery. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Clean any existing oxidation from the contact face of the battery terminal and battery cable using a wire brush before installing the battery cable to the battery terminal. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Negative) > Page 8472 1. Connect the battery negative cable to the battery. Tighten Tighten the battery negative terminal bolt to 15 N.m (11 lb ft). 2. Program the radio stations back into the radio as recorded at the beginning of the procedure. 3. Set the clock to the current time. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service Precautions > Technician Safety Information Positive: Technician Safety Information CAUTION: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions: - Air bag deployment - Personal injury - Unnecessary SIR system repairs In order to avoid the above conditions, observe the following guidelines: - Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring. - If you are performing service on or near the SIR components or the SIR wiring, disable the SIR system. Refer to Disabling the SIR System in SIR. CAUTION: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components. CAUTION: Batteries produce explosive gases, contain corrosive acid, and supply levels of electrical current high enough to cause burns. Therefore, to reduce the risk of personal injury when working near a battery: - Always shield your eyes and avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow the battery electrolyte to contact the eyes or the skin. Flush immediately and thoroughly any contacted areas with water and get medical help. - Follow each step of the jump starting procedure in order. - Treat both the booster and the discharged batteries carefully when using the jumper cables. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service Precautions > Technician Safety Information > Page 8477 Positive: Vehicle Damage Warnings NOTE: Never operate the starter motor for more than 30 seconds at a time. Allow it to cool for at least two minutes. Overheating, caused by too much cranking, will damage the starter motor. NOTE: Do not use the boost, jump start, crank, or an equivalent setting that may be available on the battery charger for prolonged charging of the battery. Using such settings may damage the battery due to overheating, excessive gassing, or spewing of electrolyte from the vents. NOTE: This vehicle has a 12 Volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 Volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service Precautions > Page 8478 Positive: Service and Repair BATTERY CABLE REPLACEMENT (POSITIVE) REMOVAL PROCEDURE IMPORTANT: When replacing battery cables be sure to use replacement cables that are the same type, gauge and length. 1. Disconnect the battery negative cable from the battery. 2. Disconnect the battery positive cable from the battery. 3. Remove the remote positive stud cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service Precautions > Page 8479 4. Remove the battery positive cable junction block lead nut (1) and disconnect the battery positive cable (2) from the underhood accessory wiring junction block. 5. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 6. Remove the battery positive cable nut (8) and disconnect the battery positive cable (9) from the starter motor BAT terminal. 7. Remove the battery cable retainers (2,3,4) from the frame. 8. Remove the battery positive cable from the wiring harness conduit. INSTALLATION PROCEDURE 1. Install the battery positive cable into the wiring harness conduit. 2. Install the battery cable retainers (2,3,4) to the frame. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service Precautions > Page 8480 3. Install the battery positive cable (9) to the starter motor BAT terminal. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the starter motor BAT terminal nut (8). Tighten Tighten the starter motor switch BAT terminal nut (8) to 10 N.m (89 lb in). 5. Lower the vehicle. 6. Install the battery positive cable (2) and the battery positive cable junction block lead nut (1) to the underhood accessory wiring junction block. Tighten Tighten the battery positive cable junction block lead nut (1) to 15 N.m (11 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service Precautions > Page 8481 7. Install the remote positive stud cover. 8. Install the batter positive cable to the battery. Tighten Tighten the battery positive cable terminal bolt to 15 N.m (11 lb ft). 9. Connect the battery negative cable to the battery. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Warranty - Generator Replacement Alternator: Technical Service Bulletins Warranty - Generator Replacement File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-03-011 Date: October, 1999 Subject: CS-144 Generator Replacement Models: 1998-2000 Passenger Cars and Trucks Beginning with the 1998 model year, General Motors stopped releasing internal repair components for the CS-144 Generator. GM warranty procedures require the replacement of the CS-144 generator. The generator unit repair procedures found in the past model Service Manuals should not be used. Use of non-GM repair parts for warranty repairs is not approved or recommended. Therefore, warranty labor claims for CS-144 generator rebuilds in the field for 1998 and newer vehicles will not be accepted. Service parts which may be available through GM for past model years, which appear to fit, should not be used. The use of correct parts is essential for proper performance of the generator. This policy change was instituted by GM to provide the best service and warranty experience for our customers. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications Alternator: Electrical Specifications Generator Model Bosch NCB1 Rated Output 125 A Load Test Output 87.5 A Generator Model Delphi CS 130D Rated Output 102 A Load Test Output 70 A Voltage Voltage Charging Voltage 13-16 Volts Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications > Page 8489 Alternator: Mechanical Specifications Generator Pulley Shaft Nut 100 Nm Generator Bolt (Long) 50 Nm Generator Bolt (Short) 50 Nm Generator Output BAT Terminal Nut 20 Nm Generator Pivot Bolt 50 Nm Generator Rear Brace Nut 25 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 8490 Alternator: Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 8491 Locations View Top of the RH side of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions Alternator: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8494 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8495 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8496 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8497 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8498 Alternator: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8499 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8500 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8501 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8502 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8503 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8504 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8505 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8506 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8507 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8508 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8509 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8510 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8511 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8512 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8513 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8514 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8515 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8516 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8517 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8518 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8519 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 8520 Generator Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service Precautions > Technician Safety Information Alternator: Technician Safety Information CAUTION: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions: - Air bag deployment - Personal injury - Unnecessary SIR system repairs In order to avoid the above conditions, observe the following guidelines: - Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring. - If you are performing service on or near the SIR components or the SIR wiring, disable the SIR system. Refer to Disabling the SIR System in SIR. CAUTION: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components. CAUTION: Batteries produce explosive gases, contain corrosive acid, and supply levels of electrical current high enough to cause burns. Therefore, to reduce the risk of personal injury when working near a battery: - Always shield your eyes and avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow the battery electrolyte to contact the eyes or the skin. Flush immediately and thoroughly any contacted areas with water and get medical help. - Follow each step of the jump starting procedure in order. - Treat both the booster and the discharged batteries carefully when using the jumper cables. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service Precautions > Technician Safety Information > Page 8523 Alternator: Vehicle Damage Warnings NOTE: Never operate the starter motor for more than 30 seconds at a time. Allow it to cool for at least two minutes. Overheating, caused by too much cranking, will damage the starter motor. NOTE: Do not use the boost, jump start, crank, or an equivalent setting that may be available on the battery charger for prolonged charging of the battery. Using such settings may damage the battery due to overheating, excessive gassing, or spewing of electrolyte from the vents. NOTE: This vehicle has a 12 Volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 Volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Replacement Alternator: Service and Repair Generator Replacement REMOVAL PROCEDURE The Delphi CS130D (K43) 102 ampere generator is serviced as a complete unit only. 1. Disconnect the battery ground (negative) cable. 2. Remove the engine compartment cross vehicle brace. 3. Remove the drive belt from the generator. 4. Place the coolant recovery reservoir aside for access. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling. 5. Remove the bolts (1,2,3) from the generator. 6. Disconnect the electrical connector from the generator. 7. Position aside the protective boot from the generator output BAT terminal. 8. Remove the generator output BAT terminal nut and disconnect the battery (positive) lead from the generator. 9. Remove the generator. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Replacement > Page 8526 1. Position the generator to the engine. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the battery (positive) lead and the generator output BAT terminal nut. Tighten Tighten the generator output BAT terminal nut to 20 N.m (15 lb ft). 3. Press the protective boot on to the generator output BAT terminal. 4. Install the electrical connector to the generator. 5. Install the generator bolt (2) and generator bolt (3) through the holes on the generator and finger start the bolts. Do not tighten the bolts. 6. Install the generator pivot bolt (1) through the generator and finger start the bolts. Do not tighten the bolt. 7. Tighten the generator bolts in the order described. The following is a mandatory torque sequence: 7.1.Tighten Tighten the generator pivot bolt (1) to 50 N.m (37 lb ft). 7.2.Tighten Tighten the generator bolt (2) to 50 N.m (37 lb ft). 7.3.Tighten Tighten the generator bolt (3) to 50 N.m (37 lb ft). 8. Install the coolant recovery reservoir. 9. Install the drive belt. 10. Install the engine compartment cross brace. 11. Connect the battery ground (negative) cable. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Replacement > Page 8527 Alternator: Service and Repair Generator Bracket Replacement REMOVAL PROCEDURE 1. Disconnect the battery negative cable from the battery. 2. Remove the generator. 3. Remove the generator bracket bolts. 4. Remove the generator bracket. 5. Remove engine lift hook. INSTALLATION PROCEDURE 1. Install engine lift hook. 2. Install the generator bracket to the engine. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install and finger tighten the generator bracket bolts. 4. Tighten the generator bracket bolts to 50 N.m (37 lb ft). 5. Install the generator. 6. Connect the battery negative cable to the battery. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Replacement > Page 8528 Alternator: Service and Repair Generator Brace Replacement REMOVAL PROCEDURE 1. Loosen the generator pivot bolt (1). 2. Remove the generator rear brace nut (4). 3. Remove the generator rear brace. INSTALLATION PROCEDURE 1. Install the generator rear brace. 2. Install the generator pivot bolt (1) finger tight. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Replacement > Page 8529 3. Install the generator rear brace nut (4) finger tight. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the generator bolt and nut as described: Tighten 4.1. Tighten the generator pivot bolt (1) to 50 N.m (37 lb ft). 4.2. Tighten the generator rear brace nut (4) to 25 N.m (18 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Switch Lock Cylinder - Dash Mounted Ignition Switch Lock Cylinder: Service and Repair Ignition Switch Lock Cylinder - Dash Mounted IGNITION SWITCH LOCK CYLINDER REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the body control module (BCM) theft deterrent relearn procedure whenever you replace the ignition switch lock cylinder. See: Body and Frame/Body Control Systems/Body Control Module/Service and Repair/Procedures/Body Control Module (BCM) Programming/RPO Configuration 1. Disconnect the negative battery cable. 2. Remove the instrument panel (I/P) cluster trim plate. 3. Insert the key and turn the ignition lock cylinder to the ON/RUN position. 4. Using a small curved tool or an L-shaped hex wrench, depress and hold the detent on the ignition lock cylinder. Access the detent by placing the tool through the I/P opening to the right of the ignition switch. If you cannot locate the detent with the tool, lower the ignition switch away from the I/P. Refer to Ignition Switch Replacement. 5. Using the key as an aid, pull to remove the lock cylinder from the switch. 6. Remove the key from the lock cylinder. 7. If the cylinder does not rotate or is seized, follow the procedure in the ignition switch replacement. Refer to Ignition Switch Replacement. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Switch Lock Cylinder - Dash Mounted > Page 8536 1. Code the ignition lock cylinder, if necessary. Refer to Key and Lock Cylinder Coding. 2. Insert the key and turn the lock cylinder to the ON/RUN position. 3. Position the lock cylinder to the ignition switch. Press the cylinder into place. If you turned the key slightly while removing the lock cylinder, you may have to align the white colored ignition switch rotor (1) with the lock cylinder (2). You can rotate the ignition switch rotor (1) with your finger. 4. Turn the key to the OFF position and remove the key. 5. Install the I/P cluster trim plate. 6. Connect the negative battery cable. 7. If you installed a new lock cylinder, perform the BCM theft deterrent relearn procedure. See: Body and Frame/Body Control Systems/Body Control Module/Service and Repair/Procedures/Body Control Module (BCM) Programming/RPO Configuration Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Switch Lock Cylinder - Dash Mounted > Page 8537 Ignition Switch Lock Cylinder: Service and Repair Programming/Learn Procedures Programming Replacement Lock Cylinder, BCM or PCM IMPORTANT: Reprogram the body control module (BCM) with the proper RPO configurations before you perform the learn procedures. When you replace the BCM, the module will learn Passlock Sensor Data Code immediately. However, the existing PCM must learn the new fuel continue password. When you replace a PCM, after programming, these modules will learn the incoming fuel continue password immediately upon receipt of a password message. Once a password message is received, and a password is learned, perform the learn procedure again if you want to change this password. A PCM which was previously installed in another vehicle will have learned the other vehicle's fuel continue password, and will require a learn procedure after programming in order to learn the current vehicle's password. 10 Minute Re-Learn Procedure Use this procedure after replacing any of the following components: 1. Lock Cylinders/Passlock Sensors 2. BCM 3. PCM Tech 2 Programming Procedure Use the following procedures in order to program the BCM with the Tech 2 equipment. 1. Connect the Tech 2 Diagnostic tool. 2. Select Request Information under Service Programming. 3. Disconnect the Tech 2 from the vehicle and connect it to a Techline Terminal. 4. On the Techline Terminal, select Theft Module Re-Learn under Service Programming. 5. Disconnect the Tech 2 from the Techline Terminal and connect the Tech 2 to the vehicle. 6. Turn ON the ignition, with the engine OFF. 7. Select VTD Re-Learn under Service Programming. 8. At this point you may disconnect the Tech 2, the Tech 2 is no longer required. 9. Observe the Security telltale, after approximately 10 minutes the telltale will turn OFF. The vehicle is now ready to relearn the Passlock Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. 10. Turn OFF the ignition, and wait 5 seconds. 11. Start the engine. (The vehicle has now learned keys). 12. Using a scan tool, clear any DTCs. 30 Minute Re-Learn Procedure Use this procedure after replacing lock cylinders, Passlock Module/BCM or the PCM (if necessary - see note above). 1. Turn ON the ignition, with the engine OFF. 2. Attempt to start the engine, then release the key to ON (The vehicle will not start). 3. Observe the Security telltale, after approximately 10 minutes the telltale will turn OFF. 4. Turn OFF the ignition, and wait 5 seconds. 5. Repeat steps 1-4 two more times, for a total of 3 cycles and 30 minutes. The vehicle is now ready to relearn the Passlock Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. IMPORTANT: The vehicle learns the Passlock Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. You must turn the ignition OFF before attempting to start the vehicle. 6. Start the engine. (The vehicle has now learned the Passlock Sensor Data Code and/or password.) 7. Using a scan tool, clear any DTCs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 8542 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 8543 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 8544 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Fastener Tightening Specifications Starter Motor: Specifications Starter Bolt(s) 43 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Fastener Tightening Specifications > Page 8549 Starter Motor: Specifications LA1 PG260 F1 L36 PG260 F2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 8550 Starter Motor: Locations Lower front of the engine. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions Starter Motor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8553 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8554 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8555 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8556 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8557 Starter Motor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8558 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8559 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8560 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8561 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8562 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8563 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8564 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8565 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8566 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8567 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8568 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8569 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8570 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8571 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8572 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8573 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8574 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8575 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8576 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8577 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8578 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service Precautions > Technician Safety Information Starter Motor: Technician Safety Information CAUTION: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions: - Air bag deployment - Personal injury - Unnecessary SIR system repairs In order to avoid the above conditions, observe the following guidelines: - Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring. - If you are performing service on or near the SIR components or the SIR wiring, disable the SIR system. Refer to Disabling the SIR System in SIR. CAUTION: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components. CAUTION: Batteries produce explosive gases, contain corrosive acid, and supply levels of electrical current high enough to cause burns. Therefore, to reduce the risk of personal injury when working near a battery: - Always shield your eyes and avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow the battery electrolyte to contact the eyes or the skin. Flush immediately and thoroughly any contacted areas with water and get medical help. - Follow each step of the jump starting procedure in order. - Treat both the booster and the discharged batteries carefully when using the jumper cables. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service Precautions > Technician Safety Information > Page 8581 Starter Motor: Vehicle Damage Warnings NOTE: Never operate the starter motor for more than 30 seconds at a time. Allow it to cool for at least two minutes. Overheating, caused by too much cranking, will damage the starter motor. NOTE: Do not use the boost, jump start, crank, or an equivalent setting that may be available on the battery charger for prolonged charging of the battery. Using such settings may damage the battery due to overheating, excessive gassing, or spewing of electrolyte from the vents. NOTE: This vehicle has a 12 Volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 Volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service Precautions > Page 8582 Starter Motor: Service and Repair STARTER MOTOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The starter motor PG260 F1 on this vehicle is NOT serviceable and must be replaced as a complete unit. 1. Disconnect the battery negative cable. 2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 3. Remove the front lower air deflector panel. 4. Remove the torque converter covers. 5. Remove the starter solenoid BAT terminal nut (8) and disconnect the positive battery cable (9) at the starter motor. 6. Remove the starter solenoid S terminal nut (7) and disconnect the starter solenoid wire (6) at the starter motor. 7. Remove the starter bolts (1,2) and the starter motor. Remove the shims, if necessary. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service Precautions > Page 8583 1. The 3.4L uses a PG260 F1 starter motor. Make sure the correct starter motor is being installed. 2. Align the starter motor to the engine. Install any shims, if removed. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the starter bolts (1,2) finger tight until seated. Tighten Tighten the starter bolts (1,2) to 43 N.m (32 lb ft). 4. Connect the positive battery cable (9) and install the solenoid BAT terminal nut (8) finger tight at the starter motor. Connect the starter solenoid wire (6) and install the starter solenoid S terminal nut (7) finger tight at the starter motor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service Precautions > Page 8584 Tighten Tighten the solenoid BAT terminal nut (8) to 9.5 N.m (84 lb in). - Tighten the starter solenoid S terminal nut (7) to 2.5 N.m (20.5 lb in). 5. Install the torque converter covers. 6. Install the front lower air deflector panel. 7. Lower the vehicle. 8. Connect the battery negative cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications Starter Solenoid: Specifications Starter Solenoid BAT Terminal Nut 9.5 Nm Starter Solenoid S Terminal Nut 2.3 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Power Outlet: > 99-08-45-005 > Nov > 99 > Accessory Receptacle/Cigar Lighter - Inoperative Auxiliary Power Outlet: Customer Interest Accessory Receptacle/Cigar Lighter - Inoperative File In Section: 08 - Body and Accessories Bulletin No.: 99-08-45-005 Date: November, 1999 TECHNICAL Subject: Accessory Receptacle/Cigar Lighter is Inoperative (Check Aftermarket Device Plug for Short to Ground) Models: 1995-2000 Passenger Cars and Trucks Condition Some customers may comment that the cigar lighter or the accessory receptacle is inoperative; or that the internal fuse (within the plug on an aftermarket device), blows intermittently. Cause Certain aftermarket devices have a newly designed power plug with an internal mini fuse. The mini fuse may have an external terminal (which may be used to externally check the fuse). If the mini fuse external test terminal is not recessed into the mini fuse body, it may come in contact with the shell of the vehicle receptacle and cause the fuse (of either the vehicle or the aftermarket device), to blow intermittently. Correction Test the aftermarket device plug for short to ground. The following step may be performed at the customer's expense. As this is not a defect in material, design or workmanship of the vehicle, it would be the owner's responsibility. 1. Place a piece of tape over the mini fuse terminal temporarily. 2. Explain to the customer that the fuse for the device must have no exposed terminals, and that finding one would be his responsibility. 3. Refer the customer to the manufacturer of the aftermarket device for a new plug. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Power Outlet: > 99-08-45-005 > Nov > 99 > Accessory Receptacle/Cigar Lighter - Inoperative Auxiliary Power Outlet: All Technical Service Bulletins Accessory Receptacle/Cigar Lighter Inoperative File In Section: 08 - Body and Accessories Bulletin No.: 99-08-45-005 Date: November, 1999 TECHNICAL Subject: Accessory Receptacle/Cigar Lighter is Inoperative (Check Aftermarket Device Plug for Short to Ground) Models: 1995-2000 Passenger Cars and Trucks Condition Some customers may comment that the cigar lighter or the accessory receptacle is inoperative; or that the internal fuse (within the plug on an aftermarket device), blows intermittently. Cause Certain aftermarket devices have a newly designed power plug with an internal mini fuse. The mini fuse may have an external terminal (which may be used to externally check the fuse). If the mini fuse external test terminal is not recessed into the mini fuse body, it may come in contact with the shell of the vehicle receptacle and cause the fuse (of either the vehicle or the aftermarket device), to blow intermittently. Correction Test the aftermarket device plug for short to ground. The following step may be performed at the customer's expense. As this is not a defect in material, design or workmanship of the vehicle, it would be the owner's responsibility. 1. Place a piece of tape over the mini fuse terminal temporarily. 2. Explain to the customer that the fuse for the device must have no exposed terminals, and that finding one would be his responsibility. 3. Refer the customer to the manufacturer of the aftermarket device for a new plug. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Auxiliary Power Connector Auxiliary Power Outlet: Locations Auxiliary Power Connector Locations View In the center console. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Auxiliary Power Connector > Page 8604 Auxiliary Power Outlet: Locations Auxiliary Power Drop Connector Taped in the I/P wiring harness, behind the RH side of the I/P Taped to I/P wiring harness above right kick panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Page 8605 Auxiliary Power Outlet: Description and Operation CIGAR LIGHTER Voltage is applied at all times to the cigar lighter through the CIG/LTR fuse in the RH IP Accessory Wiring Junction Block and the cigar lighter feed circuit. The cigar lighter has a heating element. Pushing the cigar lighter all of the way into the mounting completes the circuit to ground through the cigar lighter ground and heats the cigar lighter heating element. When the element is sufficiently heated, the cigar lighter is released from the mounting through thermal expansion of the mounting and the circuit is opened. AUXILIARY POWER OUTLET An auxiliary power outlet is provided adjacent to the cigar lighter to power customer owned and maintained equipment. Voltage is applied at all times to the auxiliary outlet through the AUX Power fuse in the RH IP Accessory Wiring Junction Block and the auxiliary power feed circuit. A ground circuit is also provided as a portion of this same outlet AUXILIARY POWER DROP CONNECTOR An auxiliary power drop connector is also provided for the installation of various types of accessories that require a more permanent type of connection. The connector, located under the right hand side of the IP, contains two B+ circuits - one supplied from the CIG/AUX fuse in the LH IP Accessory Wiring Junction Block and the other is supplied through the PWR Drop fuse in the RH IP Accessory Wiring Junction Block. A ground circuit is provided through ground G 201. A serial data communications circuit is also provided for equipment that requires the capability to communicate with control modules on the vehicle. Voltage is supplied when the ignition switch is in ACCY or Run through the CIG/AUX fuse in the LH IP Accessory Wiring Junction Block. Voltage is applied at all times to the auxiliary power drop connector through the PWR DROP fuse in the RH IP Accessory Wiring Junction Block. Ground is also supplied to the auxiliary power drop connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Auxiliary Power Outlet: Initial Inspection and Diagnostic Overview Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms in order to identify the correct procedure for diagnosing the system and where the procedure is located. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8608 Auxiliary Power Outlet: Symptom Related Diagnostic Procedures - Symptoms IMPORTANT: Review the system operation in order to familiarize yourself with the system functions. Refer to Cigar Lighter/Auxiliary Outlet Circuit Description Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the cigar lighter and auxiliary outlets. Refer to Checking Aftermarket Accessories in Diagrams. - Inspect the cigar lighter and easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent and Poor Connections in Diagrams. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Cigar Lighter Inoperative - Auxiliary Outlets Inoperative Diagnostic Chart Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8609 Diagnostic Chart (Part 1 Of 2) Diagnostic Chart (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Page 8610 Auxiliary Power Outlet: Service and Repair Power Accessory Port Replace - Front Floor Console REMOVAL PROCEDURE TOOLS REQUIRED J 42059 Cigarette Lighter Socket Remover 1. Remove the power accessory port fuse. 2. Remove the front floor console power accessory port housing from the front floor console by using a small flat-bladed tool to release the retainer. 3. Disconnect the electrical connector from the front floor console power accessory port. 4. Remove the power accessory port socket by placing one side of the "T" portion of the tool J 42059 into the tab window and then the other should be angled into the opposite tab window, then pull the power accessory port socket straight out. 5. Remove the tool from the power accessory port socket. INSTALLATION PROCEDURE 1. Align the power accessory port socket to the power accessory port housing and press into place until fully seated. 2. Connect the electrical connector to the front floor console power accessory port. 3. Position the power accessory port housing to the front floor console. 4. Install the power accessory port housing into the front floor console pressing into place until fully seated. 5. Install the power accessory port fuse. 6. Inspect the power accessory port for proper operation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations Fuse Block: Component Locations Accessory Wiring Junction Block, LH LH side of the instrument panel, in the left front door opening. Bottom Underhood Accessory Wiring Junction Block RH side of the engine compartment, forward of the strut tower. Engine Wiring Harness Junction Block (Top) RH side of the engine compartment, forward of the strut tower. Instrument Panel Fuse Block, LH Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 8619 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 8620 Locations View RPO 9C1/9C6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Instrument Panel Fuse Block, RH Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 8621 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 8622 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 8623 Locations View RPO 9C1/9C6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 8624 Locations View SEO Fuse Relay Block RH upper side of the steering column, above the knee bolster. Top Underhood Accessory Wiring Junction Block RH side of the engine compartment, forward of the strut tower. Underhood Accessory Wiring Junction Block Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 8625 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 8626 Locations View RPO 9C1/9C6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 8627 Locations View Wiring Harness Junction Block (SEO) Mounted on the RH side of the rear compartment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 8628 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) Fuse Block (SEO) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 8631 Fuse Block: Diagrams LH IP Accessory Wiring Junction Block, C1 LH IP Accessory Wiring Junction Block, C1 (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 8632 LH IP Accessory Wiring Junction Block, C1 (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 8633 Fuse Block: Diagrams LH IP Accessory Wiring Junction Block, C3 LH IP Accessory Wiring Junction Block, C3 (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 8634 LH IP Accessory Wiring Junction Block, C3 (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 8635 Fuse Block: Diagrams RH IP Accessory Wiring Junction Block, C1 RH IP Accessory Wiring Junction Block, C1 (Part 1 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 8636 RH IP Accessory Wiring Junction Block, C1 (Part 2 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 8637 RH IP Accessory Wiring Junction Block, C1 (Part 3 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 8638 Fuse Block: Diagrams RH IP Accessory Wiring Junction Block, C3 RH IP Accessory Wiring Junction Block, C3 (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 8639 RH IP Accessory Wiring Junction Block, C3 (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks Fuse Block: Application and ID Instrument Panel Fuse Blocks Instrument Panel Fuse Block, LH Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8642 Instrument Panel Fuse Block, RH Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8643 LH Instrument Panel Fuse Block Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8644 LH Instrument Panel Fuse Block, Top View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8645 LH Instrument Panel Fuse Block, Bottom View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8646 RH Instrument Panel Fuse Block Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8647 RH Instrument Panel Fuse Block, Top View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8648 RH Instrument Panel Fuse Block, Bottom View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8649 Fuse Block: Application and ID Electrical Centers Top Underhood Electrical Center Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8650 Top Underhood Electrical Center, Top View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8651 Top Underhood Electrical Center, Bottom View Bottom Underhood Electrical Center Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8652 Bottom Underhood Electrical Center, Top View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8653 Bottom Underhood Electrical Center, Bottom View Underhood Electrical Center, Top Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8654 Underhood Electrical Center, Bottom Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Relay/Fuse Center Replacement (Left) Fuse Block: Service and Repair Relay/Fuse Center Replacement (Left) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Adjust the instrument panel (IP) cluster trim plate for access. 3. Disconnect the body wiring harness from the junction block. 4. Remove the junction block bolts. 5. Remove the junction block tab from the slot in the cross vehicle beam. Pull the junction block away from the IP. 6. Disconnect the body wiring harness from the junction block. 7. Remove the junction block. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Relay/Fuse Center Replacement (Left) > Page 8657 1. Connect the body wiring harness to the junction block. 2. Install the junction block tab to the slot in the cross vehicle beam. 3. Install the junction block bolts. Tighten Tighten the junction block bolts to 10 N.m (89 lb in). 4. Connect the body wiring harness to the junction block. Tighten Tighten the body wiring harness connector bolt to 7 N.m (62 lb in). 5. Install the instrument panel (IP) cluster trim plate. 6. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Relay/Fuse Center Replacement (Left) > Page 8658 Fuse Block: Service and Repair Relay/Fuse Center Replacement (Right) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the RH instrument panel (IP) fuse block access opening cover. 3. Remove the IP compartment. 4. Disconnect the body wiring harness from the junction block. 5. Remove the junction block bolt. 6. Disengage the junction block tabs from the passenger knee bolster. Pull the junction block away from the IP. 7. Disconnect the wiring harnesses from the junction block. 8. Remove the junction block. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Relay/Fuse Center Replacement (Left) > Page 8659 1. Connect the body wiring harnesses to the junction block. Tighten Tighten the body wiring harness connector bolts to 7 N.m (62 lb in). 2. Install the junction block tabs to the passenger knee bolster. 3. Install the junction block bolt. Tighten Tighten the junction block bolt to 10 N.m (89 lb in). 4. Connect the body wiring harness to the junction block. 5. Install the instrument panel (IP) compartment. 6. Install the RH IP fuse block access opening cover. 7. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fusible Links, IP Harness Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8668 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8669 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8670 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8671 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8672 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8673 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Multiple Junction Connector: Customer Interest BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 8682 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Multiple Junction Connector: All Technical Service Bulletins BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 8688 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 Multiple Junction Connector: Diagrams C100 - C199 C101 (W/ RPO LA1) Inline Connector C101 RPO LA1: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8691 Inline Connector C102 Inline Connector C104 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8692 Inline Connector C106 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8693 Inline Connector C110 C112 (24 cavities) Instrument panel harness to engine harness. (24 cavities) Engine harness to forward lamp harness RH side of engine. (24 cavities) Engine wiring harness to the forward lamp wiring harness, LH front side of the engine compartment Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8694 Inline Connector C113 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8695 Inline Connector C120 Inline Connector C125 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8696 Inline Connector C126 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8697 Multiple Junction Connector: Diagrams C200 - C299 Inline Connector C201 (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8698 Inline Connector C201 (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8699 Inline Connector C203 Inline Connector C205 (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8700 Inline Connector C205 (Part 2 Of 2) Inline Connector C209A (SEO) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8701 Inline Connector C209B (SEO) Inline Connector C215 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8702 Inline Connector C216 Inline Connector C218 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8703 Inline Connector C220 Inline Connector C240 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8704 Inline Connector C255 (SEO) Inline Connector C297 (SEO) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8705 Inline Connector C299A (SEO) Inline Connector C299B (SEO) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8706 Multiple Junction Connector: Diagrams C300 - C399 Inline Connector C301 (2 Door) (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8707 Inline Connector C301 (2 Door) (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8708 Inline Connector C301 (4-Door) (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8709 Inline Connector C301 (4-Door) (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8710 Inline Connector C302 (2 Door) (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8711 Inline Connector C302 (2 Door) (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8712 Inline Connector C302 (4 Door) (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8713 Inline Connector C302 (4 Door) (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8714 Inline Connector C306 (SEO) Inline Connector C308 (SEO) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8715 Inline Connector C312 Inline Connector C315 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8716 Inline Connector C317 Inline Connector C355 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8717 Inline Connector C356 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8718 Inline Connector C373 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8719 Multiple Junction Connector: Diagrams C400 - C499 Inline Connector C400 (2 Door) Inline Connector C400 (4 Door) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8720 Inline Connector C401 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8721 Inline Connector C405 Inline Connector C409 (SEO) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8722 Inline Connector C430 Inline Connector C435 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8731 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8732 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8733 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-049B > Dec > 03 > Electrical - SES Lamp ON/Driveability/No Start/DTC's Set Wiring Harness: Customer Interest Electrical - SES Lamp ON/Driveability/No Start/DTC's Set Bulletin No.: 00-06-04-049B Date: December 19, 2003 TECHNICAL Subject: Various Driveability Symptoms - Malfunction Indicator Lamp (MIL) Illuminates Intermittently, ABS Light On, DTCs Set, Engine Will Not Start (Repair Wire(s)) Models: 1997-2003 Buick Century, Regal Built Prior to 2/03 2000-2003 Chevrolet Impala, Monte Carlo Built Prior to 2/03 1999-2001 Pontiac Grand Prix Built Prior to 10/1/00 - VIN Breakpoint 1F136536 Supercede: This bulletin is being revised to add additional models and model years and to include possible ABS indicator illuminated. Please discard Corporate Bulletin Number 00-06-04-049A (Section 06 Engine). Condition Some customers may comment on one or more of the following conditions: ^ Anti-Lock Brake System Warning Light illuminated ^ Intermittent MIL/Service Engine Soon indicator illuminated ^ Engine will not start ^ Engine stalls after start up ^ Various electrical system failures ^ Various driveability concerns Cause These conditions may be caused from the engine wiring harness chaffing against the mounting ring on the A/C accumulator. This contact may cause a rub through to the wires enclosed in that harness, resulting in the above conditions. Damage to the harness may also result in several stored diagnostic trouble codes. Correction Inspect and repair any damaged wires. Use the procedure listed below. Note: Do not install plastic conduit over the repaired area. Doing so may damage the A/C accumulator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-049B > Dec > 03 > Electrical - SES Lamp ON/Driveability/No Start/DTC's Set > Page 8738 1. Inspect and repair any damaged wires at the suspected area (1). Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Wrap the repaired area with 3M(R) Electrical Moisture Sealant Patches, P/N 06149, or equivalent. Wrap the entire area of contact with friction material , P/N 22617849, to protect it from future damage. 2. Verify proper installation of the harness clamp that attaches the harness to the transmission. Reinstall if necessary. 3. Reposition the repaired harness away from the A/C accumulator. Pull the harness through the clamp at the transmission to remove any slack. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-049B > Dec > 03 > Electrical - SES Lamp ON/Driveability/No Start/DTC's Set > Page 8739 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8745 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8746 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8747 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8752 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8753 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8754 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8755 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8756 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8757 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 8762 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 00-06-04-049B > Dec > 03 > Electrical - SES Lamp ON/Driveability/No Start/DTC's Set Wiring Harness: All Technical Service Bulletins Electrical - SES Lamp ON/Driveability/No Start/DTC's Set Bulletin No.: 00-06-04-049B Date: December 19, 2003 TECHNICAL Subject: Various Driveability Symptoms - Malfunction Indicator Lamp (MIL) Illuminates Intermittently, ABS Light On, DTCs Set, Engine Will Not Start (Repair Wire(s)) Models: 1997-2003 Buick Century, Regal Built Prior to 2/03 2000-2003 Chevrolet Impala, Monte Carlo Built Prior to 2/03 1999-2001 Pontiac Grand Prix Built Prior to 10/1/00 - VIN Breakpoint 1F136536 Supercede: This bulletin is being revised to add additional models and model years and to include possible ABS indicator illuminated. Please discard Corporate Bulletin Number 00-06-04-049A (Section 06 Engine). Condition Some customers may comment on one or more of the following conditions: ^ Anti-Lock Brake System Warning Light illuminated ^ Intermittent MIL/Service Engine Soon indicator illuminated ^ Engine will not start ^ Engine stalls after start up ^ Various electrical system failures ^ Various driveability concerns Cause These conditions may be caused from the engine wiring harness chaffing against the mounting ring on the A/C accumulator. This contact may cause a rub through to the wires enclosed in that harness, resulting in the above conditions. Damage to the harness may also result in several stored diagnostic trouble codes. Correction Inspect and repair any damaged wires. Use the procedure listed below. Note: Do not install plastic conduit over the repaired area. Doing so may damage the A/C accumulator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 00-06-04-049B > Dec > 03 > Electrical - SES Lamp ON/Driveability/No Start/DTC's Set > Page 8767 1. Inspect and repair any damaged wires at the suspected area (1). Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Wrap the repaired area with 3M(R) Electrical Moisture Sealant Patches, P/N 06149, or equivalent. Wrap the entire area of contact with friction material , P/N 22617849, to protect it from future damage. 2. Verify proper installation of the harness clamp that attaches the harness to the transmission. Reinstall if necessary. 3. Reposition the repaired harness away from the A/C accumulator. Pull the harness through the clamp at the transmission to remove any slack. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 00-06-04-049B > Dec > 03 > Electrical - SES Lamp ON/Driveability/No Start/DTC's Set > Page 8768 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8774 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8775 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8776 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8777 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8778 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8779 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 8784 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Power Outlet: > 99-08-45-005 > Nov > 99 > Accessory Receptacle/Cigar Lighter - Inoperative Auxiliary Power Outlet: Customer Interest Accessory Receptacle/Cigar Lighter - Inoperative File In Section: 08 - Body and Accessories Bulletin No.: 99-08-45-005 Date: November, 1999 TECHNICAL Subject: Accessory Receptacle/Cigar Lighter is Inoperative (Check Aftermarket Device Plug for Short to Ground) Models: 1995-2000 Passenger Cars and Trucks Condition Some customers may comment that the cigar lighter or the accessory receptacle is inoperative; or that the internal fuse (within the plug on an aftermarket device), blows intermittently. Cause Certain aftermarket devices have a newly designed power plug with an internal mini fuse. The mini fuse may have an external terminal (which may be used to externally check the fuse). If the mini fuse external test terminal is not recessed into the mini fuse body, it may come in contact with the shell of the vehicle receptacle and cause the fuse (of either the vehicle or the aftermarket device), to blow intermittently. Correction Test the aftermarket device plug for short to ground. The following step may be performed at the customer's expense. As this is not a defect in material, design or workmanship of the vehicle, it would be the owner's responsibility. 1. Place a piece of tape over the mini fuse terminal temporarily. 2. Explain to the customer that the fuse for the device must have no exposed terminals, and that finding one would be his responsibility. 3. Refer the customer to the manufacturer of the aftermarket device for a new plug. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Power Outlet: > 99-08-45-005 > Nov > 99 > Accessory Receptacle/Cigar Lighter - Inoperative Auxiliary Power Outlet: All Technical Service Bulletins Accessory Receptacle/Cigar Lighter Inoperative File In Section: 08 - Body and Accessories Bulletin No.: 99-08-45-005 Date: November, 1999 TECHNICAL Subject: Accessory Receptacle/Cigar Lighter is Inoperative (Check Aftermarket Device Plug for Short to Ground) Models: 1995-2000 Passenger Cars and Trucks Condition Some customers may comment that the cigar lighter or the accessory receptacle is inoperative; or that the internal fuse (within the plug on an aftermarket device), blows intermittently. Cause Certain aftermarket devices have a newly designed power plug with an internal mini fuse. The mini fuse may have an external terminal (which may be used to externally check the fuse). If the mini fuse external test terminal is not recessed into the mini fuse body, it may come in contact with the shell of the vehicle receptacle and cause the fuse (of either the vehicle or the aftermarket device), to blow intermittently. Correction Test the aftermarket device plug for short to ground. The following step may be performed at the customer's expense. As this is not a defect in material, design or workmanship of the vehicle, it would be the owner's responsibility. 1. Place a piece of tape over the mini fuse terminal temporarily. 2. Explain to the customer that the fuse for the device must have no exposed terminals, and that finding one would be his responsibility. 3. Refer the customer to the manufacturer of the aftermarket device for a new plug. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Auxiliary Power Connector Auxiliary Power Outlet: Locations Auxiliary Power Connector Locations View In the center console. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Auxiliary Power Connector > Page 8801 Auxiliary Power Outlet: Locations Auxiliary Power Drop Connector Taped in the I/P wiring harness, behind the RH side of the I/P Taped to I/P wiring harness above right kick panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Page 8802 Auxiliary Power Outlet: Description and Operation CIGAR LIGHTER Voltage is applied at all times to the cigar lighter through the CIG/LTR fuse in the RH IP Accessory Wiring Junction Block and the cigar lighter feed circuit. The cigar lighter has a heating element. Pushing the cigar lighter all of the way into the mounting completes the circuit to ground through the cigar lighter ground and heats the cigar lighter heating element. When the element is sufficiently heated, the cigar lighter is released from the mounting through thermal expansion of the mounting and the circuit is opened. AUXILIARY POWER OUTLET An auxiliary power outlet is provided adjacent to the cigar lighter to power customer owned and maintained equipment. Voltage is applied at all times to the auxiliary outlet through the AUX Power fuse in the RH IP Accessory Wiring Junction Block and the auxiliary power feed circuit. A ground circuit is also provided as a portion of this same outlet AUXILIARY POWER DROP CONNECTOR An auxiliary power drop connector is also provided for the installation of various types of accessories that require a more permanent type of connection. The connector, located under the right hand side of the IP, contains two B+ circuits - one supplied from the CIG/AUX fuse in the LH IP Accessory Wiring Junction Block and the other is supplied through the PWR Drop fuse in the RH IP Accessory Wiring Junction Block. A ground circuit is provided through ground G 201. A serial data communications circuit is also provided for equipment that requires the capability to communicate with control modules on the vehicle. Voltage is supplied when the ignition switch is in ACCY or Run through the CIG/AUX fuse in the LH IP Accessory Wiring Junction Block. Voltage is applied at all times to the auxiliary power drop connector through the PWR DROP fuse in the RH IP Accessory Wiring Junction Block. Ground is also supplied to the auxiliary power drop connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Auxiliary Power Outlet: Initial Inspection and Diagnostic Overview Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms in order to identify the correct procedure for diagnosing the system and where the procedure is located. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8805 Auxiliary Power Outlet: Symptom Related Diagnostic Procedures - Symptoms IMPORTANT: Review the system operation in order to familiarize yourself with the system functions. Refer to Cigar Lighter/Auxiliary Outlet Circuit Description Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the cigar lighter and auxiliary outlets. Refer to Checking Aftermarket Accessories in Diagrams. - Inspect the cigar lighter and easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent and Poor Connections in Diagrams. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Cigar Lighter Inoperative - Auxiliary Outlets Inoperative Diagnostic Chart Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8806 Diagnostic Chart (Part 1 Of 2) Diagnostic Chart (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Page 8807 Auxiliary Power Outlet: Service and Repair Power Accessory Port Replace - Front Floor Console REMOVAL PROCEDURE TOOLS REQUIRED J 42059 Cigarette Lighter Socket Remover 1. Remove the power accessory port fuse. 2. Remove the front floor console power accessory port housing from the front floor console by using a small flat-bladed tool to release the retainer. 3. Disconnect the electrical connector from the front floor console power accessory port. 4. Remove the power accessory port socket by placing one side of the "T" portion of the tool J 42059 into the tab window and then the other should be angled into the opposite tab window, then pull the power accessory port socket straight out. 5. Remove the tool from the power accessory port socket. INSTALLATION PROCEDURE 1. Align the power accessory port socket to the power accessory port housing and press into place until fully seated. 2. Connect the electrical connector to the front floor console power accessory port. 3. Position the power accessory port housing to the front floor console. 4. Install the power accessory port housing into the front floor console pressing into place until fully seated. 5. Install the power accessory port fuse. 6. Inspect the power accessory port for proper operation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations Fuse Block: Component Locations Accessory Wiring Junction Block, LH LH side of the instrument panel, in the left front door opening. Bottom Underhood Accessory Wiring Junction Block RH side of the engine compartment, forward of the strut tower. Engine Wiring Harness Junction Block (Top) RH side of the engine compartment, forward of the strut tower. Instrument Panel Fuse Block, LH Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 8816 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 8817 Locations View RPO 9C1/9C6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Instrument Panel Fuse Block, RH Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 8818 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 8819 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 8820 Locations View RPO 9C1/9C6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 8821 Locations View SEO Fuse Relay Block RH upper side of the steering column, above the knee bolster. Top Underhood Accessory Wiring Junction Block RH side of the engine compartment, forward of the strut tower. Underhood Accessory Wiring Junction Block Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 8822 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 8823 Locations View RPO 9C1/9C6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 8824 Locations View Wiring Harness Junction Block (SEO) Mounted on the RH side of the rear compartment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 8825 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) Fuse Block (SEO) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 8828 Fuse Block: Diagrams LH IP Accessory Wiring Junction Block, C1 LH IP Accessory Wiring Junction Block, C1 (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 8829 LH IP Accessory Wiring Junction Block, C1 (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 8830 Fuse Block: Diagrams LH IP Accessory Wiring Junction Block, C3 LH IP Accessory Wiring Junction Block, C3 (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 8831 LH IP Accessory Wiring Junction Block, C3 (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 8832 Fuse Block: Diagrams RH IP Accessory Wiring Junction Block, C1 RH IP Accessory Wiring Junction Block, C1 (Part 1 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 8833 RH IP Accessory Wiring Junction Block, C1 (Part 2 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 8834 RH IP Accessory Wiring Junction Block, C1 (Part 3 Of 3) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 8835 Fuse Block: Diagrams RH IP Accessory Wiring Junction Block, C3 RH IP Accessory Wiring Junction Block, C3 (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block (SEO) > Page 8836 RH IP Accessory Wiring Junction Block, C3 (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks Fuse Block: Application and ID Instrument Panel Fuse Blocks Instrument Panel Fuse Block, LH Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8839 Instrument Panel Fuse Block, RH Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8840 LH Instrument Panel Fuse Block Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8841 LH Instrument Panel Fuse Block, Top View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8842 LH Instrument Panel Fuse Block, Bottom View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8843 RH Instrument Panel Fuse Block Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8844 RH Instrument Panel Fuse Block, Top View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8845 RH Instrument Panel Fuse Block, Bottom View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8846 Fuse Block: Application and ID Electrical Centers Top Underhood Electrical Center Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8847 Top Underhood Electrical Center, Top View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8848 Top Underhood Electrical Center, Bottom View Bottom Underhood Electrical Center Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8849 Bottom Underhood Electrical Center, Top View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8850 Bottom Underhood Electrical Center, Bottom View Underhood Electrical Center, Top Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel Fuse Blocks > Page 8851 Underhood Electrical Center, Bottom Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Relay/Fuse Center Replacement (Left) Fuse Block: Service and Repair Relay/Fuse Center Replacement (Left) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Adjust the instrument panel (IP) cluster trim plate for access. 3. Disconnect the body wiring harness from the junction block. 4. Remove the junction block bolts. 5. Remove the junction block tab from the slot in the cross vehicle beam. Pull the junction block away from the IP. 6. Disconnect the body wiring harness from the junction block. 7. Remove the junction block. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Relay/Fuse Center Replacement (Left) > Page 8854 1. Connect the body wiring harness to the junction block. 2. Install the junction block tab to the slot in the cross vehicle beam. 3. Install the junction block bolts. Tighten Tighten the junction block bolts to 10 N.m (89 lb in). 4. Connect the body wiring harness to the junction block. Tighten Tighten the body wiring harness connector bolt to 7 N.m (62 lb in). 5. Install the instrument panel (IP) cluster trim plate. 6. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Relay/Fuse Center Replacement (Left) > Page 8855 Fuse Block: Service and Repair Relay/Fuse Center Replacement (Right) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the RH instrument panel (IP) fuse block access opening cover. 3. Remove the IP compartment. 4. Disconnect the body wiring harness from the junction block. 5. Remove the junction block bolt. 6. Disengage the junction block tabs from the passenger knee bolster. Pull the junction block away from the IP. 7. Disconnect the wiring harnesses from the junction block. 8. Remove the junction block. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Relay/Fuse Center Replacement (Left) > Page 8856 1. Connect the body wiring harnesses to the junction block. Tighten Tighten the body wiring harness connector bolts to 7 N.m (62 lb in). 2. Install the junction block tabs to the passenger knee bolster. 3. Install the junction block bolt. Tighten Tighten the junction block bolt to 10 N.m (89 lb in). 4. Connect the body wiring harness to the junction block. 5. Install the instrument panel (IP) compartment. 6. Install the RH IP fuse block access opening cover. 7. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fusible Links, IP Harness Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8865 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8866 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8867 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8868 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8869 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8870 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 04-08-47-003 > Aug > 04 > BCM Security Lamp ON/No Crank/DTC's Set Multiple Junction Connector: Customer Interest BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 04-08-47-003 > Aug > 04 > BCM Security Lamp ON/No Crank/DTC's Set > Page 8879 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Multiple Junction Connector: All Technical Service Bulletins BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 8885 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 Multiple Junction Connector: Diagrams C100 - C199 C101 (W/ RPO LA1) Inline Connector C101 RPO LA1: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8888 Inline Connector C102 Inline Connector C104 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8889 Inline Connector C106 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8890 Inline Connector C110 C112 (24 cavities) Instrument panel harness to engine harness. (24 cavities) Engine harness to forward lamp harness RH side of engine. (24 cavities) Engine wiring harness to the forward lamp wiring harness, LH front side of the engine compartment Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8891 Inline Connector C113 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8892 Inline Connector C120 Inline Connector C125 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8893 Inline Connector C126 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8894 Multiple Junction Connector: Diagrams C200 - C299 Inline Connector C201 (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8895 Inline Connector C201 (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8896 Inline Connector C203 Inline Connector C205 (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8897 Inline Connector C205 (Part 2 Of 2) Inline Connector C209A (SEO) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8898 Inline Connector C209B (SEO) Inline Connector C215 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8899 Inline Connector C216 Inline Connector C218 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8900 Inline Connector C220 Inline Connector C240 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8901 Inline Connector C255 (SEO) Inline Connector C297 (SEO) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8902 Inline Connector C299A (SEO) Inline Connector C299B (SEO) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8903 Multiple Junction Connector: Diagrams C300 - C399 Inline Connector C301 (2 Door) (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8904 Inline Connector C301 (2 Door) (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8905 Inline Connector C301 (4-Door) (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8906 Inline Connector C301 (4-Door) (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8907 Inline Connector C302 (2 Door) (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8908 Inline Connector C302 (2 Door) (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8909 Inline Connector C302 (4 Door) (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8910 Inline Connector C302 (4 Door) (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8911 Inline Connector C306 (SEO) Inline Connector C308 (SEO) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8912 Inline Connector C312 Inline Connector C315 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8913 Inline Connector C317 Inline Connector C355 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8914 Inline Connector C356 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8915 Inline Connector C373 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8916 Multiple Junction Connector: Diagrams C400 - C499 Inline Connector C400 (2 Door) Inline Connector C400 (4 Door) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8917 Inline Connector C401 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8918 Inline Connector C405 Inline Connector C409 (SEO) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 8919 Inline Connector C430 Inline Connector C435 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8928 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8929 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8930 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-049B > Dec > 03 > Electrical - SES Lamp ON/Driveability/No Start/DTC's Set Wiring Harness: Customer Interest Electrical - SES Lamp ON/Driveability/No Start/DTC's Set Bulletin No.: 00-06-04-049B Date: December 19, 2003 TECHNICAL Subject: Various Driveability Symptoms - Malfunction Indicator Lamp (MIL) Illuminates Intermittently, ABS Light On, DTCs Set, Engine Will Not Start (Repair Wire(s)) Models: 1997-2003 Buick Century, Regal Built Prior to 2/03 2000-2003 Chevrolet Impala, Monte Carlo Built Prior to 2/03 1999-2001 Pontiac Grand Prix Built Prior to 10/1/00 - VIN Breakpoint 1F136536 Supercede: This bulletin is being revised to add additional models and model years and to include possible ABS indicator illuminated. Please discard Corporate Bulletin Number 00-06-04-049A (Section 06 Engine). Condition Some customers may comment on one or more of the following conditions: ^ Anti-Lock Brake System Warning Light illuminated ^ Intermittent MIL/Service Engine Soon indicator illuminated ^ Engine will not start ^ Engine stalls after start up ^ Various electrical system failures ^ Various driveability concerns Cause These conditions may be caused from the engine wiring harness chaffing against the mounting ring on the A/C accumulator. This contact may cause a rub through to the wires enclosed in that harness, resulting in the above conditions. Damage to the harness may also result in several stored diagnostic trouble codes. Correction Inspect and repair any damaged wires. Use the procedure listed below. Note: Do not install plastic conduit over the repaired area. Doing so may damage the A/C accumulator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-049B > Dec > 03 > Electrical - SES Lamp ON/Driveability/No Start/DTC's Set > Page 8935 1. Inspect and repair any damaged wires at the suspected area (1). Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Wrap the repaired area with 3M(R) Electrical Moisture Sealant Patches, P/N 06149, or equivalent. Wrap the entire area of contact with friction material , P/N 22617849, to protect it from future damage. 2. Verify proper installation of the harness clamp that attaches the harness to the transmission. Reinstall if necessary. 3. Reposition the repaired harness away from the A/C accumulator. Pull the harness through the clamp at the transmission to remove any slack. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-049B > Dec > 03 > Electrical - SES Lamp ON/Driveability/No Start/DTC's Set > Page 8936 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8942 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8943 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8944 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8949 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8950 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8951 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8952 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8953 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8954 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 8959 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 00-06-04-049B > Dec > 03 > Electrical - SES Lamp ON/Driveability/No Start/DTC's Set Wiring Harness: All Technical Service Bulletins Electrical - SES Lamp ON/Driveability/No Start/DTC's Set Bulletin No.: 00-06-04-049B Date: December 19, 2003 TECHNICAL Subject: Various Driveability Symptoms - Malfunction Indicator Lamp (MIL) Illuminates Intermittently, ABS Light On, DTCs Set, Engine Will Not Start (Repair Wire(s)) Models: 1997-2003 Buick Century, Regal Built Prior to 2/03 2000-2003 Chevrolet Impala, Monte Carlo Built Prior to 2/03 1999-2001 Pontiac Grand Prix Built Prior to 10/1/00 - VIN Breakpoint 1F136536 Supercede: This bulletin is being revised to add additional models and model years and to include possible ABS indicator illuminated. Please discard Corporate Bulletin Number 00-06-04-049A (Section 06 Engine). Condition Some customers may comment on one or more of the following conditions: ^ Anti-Lock Brake System Warning Light illuminated ^ Intermittent MIL/Service Engine Soon indicator illuminated ^ Engine will not start ^ Engine stalls after start up ^ Various electrical system failures ^ Various driveability concerns Cause These conditions may be caused from the engine wiring harness chaffing against the mounting ring on the A/C accumulator. This contact may cause a rub through to the wires enclosed in that harness, resulting in the above conditions. Damage to the harness may also result in several stored diagnostic trouble codes. Correction Inspect and repair any damaged wires. Use the procedure listed below. Note: Do not install plastic conduit over the repaired area. Doing so may damage the A/C accumulator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 00-06-04-049B > Dec > 03 > Electrical - SES Lamp ON/Driveability/No Start/DTC's Set > Page 8964 1. Inspect and repair any damaged wires at the suspected area (1). Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Wrap the repaired area with 3M(R) Electrical Moisture Sealant Patches, P/N 06149, or equivalent. Wrap the entire area of contact with friction material , P/N 22617849, to protect it from future damage. 2. Verify proper installation of the harness clamp that attaches the harness to the transmission. Reinstall if necessary. 3. Reposition the repaired harness away from the A/C accumulator. Pull the harness through the clamp at the transmission to remove any slack. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 00-06-04-049B > Dec > 03 > Electrical - SES Lamp ON/Driveability/No Start/DTC's Set > Page 8965 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8971 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8972 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8973 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8974 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8975 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8976 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 8981 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8987 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8988 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8989 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8990 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8991 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8992 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8993 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Wheel Alignment Specifications Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Wheel Alignment Specifications > Page 8996 Alignment: Specifications Ride/Trim Height Specifications Trim Height Specifications Measuring Z Height Measuring D Height Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Wheel Alignment Specifications > Page 8997 Measuring J or K Height Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Wheel Alignment Specifications > Page 8998 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber Description Alignment: Description and Operation Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, as shown, the camber is positive (+). When the wheels tilt inward, the camber is negative (-). The amount of tilt measured in degrees from the vertical is known as the camber angle. Camber influences both directional control and tire wear. Excessive camber results in tire wear and causes the vehicle to pull or lead to the side with the most positive camber. Camber adjustment is available at both the front and the rear wheels. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber Description > Page 9001 Alignment: Description and Operation Caster Description Caster is the tilting of the uppermost point of the steering axis, either forward or backward from the vertical, when viewed from the side of the vehicle. A backward tilt at the top is positive (+) and a forward tilt is negative (-). Caster influences the directional control of the steering, but caster does not affect tire wear. One wheel with more positive caster than the other wheel causes that wheel to pull toward the center of the vehicle. The vehicle will move or lead toward that side with the least amount of positive caster. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber Description > Page 9002 Alignment: Description and Operation Toe Description Toe-in is the turning-in of the wheels, while toe-out is the turning-out of the wheels from the geometric centerline/thrust line. The purpose of toe is to ensure parallel rolling of the wheels. Toe also serves to offset the small deflections of the wheel support system which occur whenever the vehicle is rolling forward. Even when the wheels are set to toe-in or toe-out, the wheels tend to roll parallel on the road when the vehicle is moving. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber Description > Page 9003 Alignment: Description and Operation Thrust Angle Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle. The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line off center. The resulting deviation (3) from the centerline is the thrust angle (1). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber Description > Page 9004 Alignment: Description and Operation Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, as shown, the camber is positive (+). When the wheels tilt inward, the camber is negative (-). The amount of tilt measured in degrees from the vertical is known as the camber angle. Camber influences both directional control and tire wear. Excessive camber results in tire wear and causes the vehicle to pull or lead to the side with the most positive camber. Camber adjustment is available at both the front and the rear wheels. Caster Description Caster is the tilting of the uppermost point of the steering axis, either forward or backward from the vertical, when viewed from the side of the vehicle. A backward tilt at the top is positive (+) and a forward tilt is negative (-). Caster influences the directional control of the steering, but caster does not affect tire wear. One wheel with more positive caster than the other wheel causes that wheel to pull toward the center of the vehicle. The vehicle will move or lead toward that side with the least amount of positive caster. Toe Description Toe-in is the turning-in of the wheels, while toe-out is the turning-out of the wheels from the geometric centerline/thrust line. The purpose of toe is to Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber Description > Page 9005 ensure parallel rolling of the wheels. Toe also serves to offset the small deflections of the wheel support system which occur whenever the vehicle is rolling forward. Even when the wheels are set to toe-in or toe-out, the wheels tend to roll parallel on the road when the vehicle is moving. Thrust Angle Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle. The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line off center. The resulting deviation (3) from the centerline is the thrust angle (1). Frame Misalignment Description The frame is a rubber isolated sub-frame in the front of the vehicle. The frame supports the engine and the transaxle. The frame provides the mounting point for the front suspension lower control arms. The frame in the upper illustration is normal. Any misalignment of the frame, as shown, causes a misalignment of the front wheels. Movement of the frame usually causes an increase in caster on one side of the vehicle and a decrease in caster on the other side of the vehicle. This can cause the following conditions: Cause the exhaust system to bind up - Cause problems with the control cables - Cause unacceptable noises and/or sounds Check the frame for any obvious damage. In the illustration, the frame (1) is moved toward the rear. The left lower control arm and the left ball joint are moved toward the rear, changing the caster on the left side only. The top of the strut cannot move because the strut is mounted to the strut tower in the body. General Description Wheel alignment refers to the angular relationship between the following: The wheels - The suspension attaching parts - The ground Four Wheel Alignment Perform a complete wheel alignment check whenever a service check is deemed necessary. This check includes the measurement of all four wheels. The fuel economy and the tire life increases when the vehicle is geometrically aligned. Additionally, the steering and the performance maximize. Lead/Pull Description Lead is the deviation of the vehicle from a straight path on a level road, without hand pressure on the steering wheel. Lead is usually the result of one of the following conditions: 1. Tire construction. Refer to Vibration Diagnosis and Correction under Steering and Suspension Testing and Inspection. Refer also to General Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber Description > Page 9006 Description in Wheels, Tires and Alignment. 2. Uneven parking brake adjustment. Refer to Park Brake Cable Service/Adjustment in Brakes. 3. Wheel Alignment The way in which a tire is built may produce lead. Rear tires do not cause lead. Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel spindle may be aligned behind the other wheel spindle. In the illustration, the left side frame (1) is moved toward the rear, causing a misalignment. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than one degree. Torque Steer Description A vehicle pulls or leads in one direction during hard acceleration. A vehicle pulls or leads in the other direction during deceleration. The following factors may cause torque steer to be more apparent on a particular vehicle: A slightly smaller diameter tire on the right front increases a right torque lead. Inspect the front tires for differences in the brand, the construction, or the size. If the tires appear to be similar, change the front tires from side-to-side and retest the vehicle. Tire and wheel assemblies have the most significant effect on torque steer correction. - A large difference in the right and left front tire pressure - Left-to-right differences in the front view axle angle may cause significant steering pull in a vehicle. The pull will be to the side with the most downward sloping axle from the differential to the wheels. Axles typically slope downward from the differential. The slope of the transaxle pan to level ground may be used as an indication of bias axle angles. The side with the higher transaxle pan (shown on the left side of the illustration) has the most downward sloping axle angle. Wander Description Wander is the undesirable drifting or deviation of a vehicle toward either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of a vehicle's sensitivity to external disturbances, such as road crown and crosswind. A poor, on-center steering feel accentuates a wander condition. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Alignment Inspection Alignment: Service and Repair Preliminary Alignment Inspection Loose and worn suspension parts prevents an accurate setting of alignment angles. Before you make any alignment adjustments, ensure the correctness of the alignment readings and the adjustments: Check the tires for proper inflation pressures. Refer to Tire Inflation Pressure Specifications. - Check the tires for normal tread wear. - Check the hub and bearing for excessive wear. - Check the ball joints and the tie rods for looseness. - Inspect the wheels and tires for runout, resulting from bent wheels or faulty tires. - Inspect vehicle trim heights. If the trim heights are not within specifications, make necessary corrections before adjusting the alignment. Refer to Trim Height Specifications in Suspension General Diagnosis. - Check the steering gear for looseness at the frame. - Check the struts for improper operation. - Inspect the control arms for loose or worn bushings. - Check the stabilizer shaft attachments for loose or missing components. - Check the alignment pins for improper frame alignment to the body. - Check the frame fasteners for proper torque. - Check the frame insulators for wear or damage. Before checking the alignment, become familiar with the instructions that are furnished by the equipment manufacturer. Methods will vary with different equipment. Regardless of the equipment used for adjusting the alignment, always keep the vehicle on a level surface, both fore-and-aft and sideways. Important: - Check and set the alignment with a full fuel tank. - Jounce the vehicle three times before you check the alignment in order to eliminate false readings. - Hold the front and the rear suspensions to the specified dimensions. Refer to Trim Height Specifications in Suspension General Diagnosis. - Set the toe left side adjustment and the toe right side adjustment separately per wheel. Hold the steering wheel level at O degrees plus or minus 3.5 degrees. Cross caster within 0.75 degrees. - Cross camber within 0.75 degrees. Adjust Perform four wheel alignment adjustments in the following order: 1. Rear wheel camber 2. Rear wheel toe and tracking 3. Front wheel camber 4. Front wheel toe and steering wheel angle Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Alignment Inspection > Page 9009 Alignment: Service and Repair Pre-Alignment Road Test With Customer Perform a road test on the vehicle with the customer. The road test may help to identify many faulty parts: - Worn control arm bushings or strut bearings - Weak strut dampeners - Loose power steering gear mounts - Wheel bearings - Tires Obvious conditions must be brought to the customer's attention before beginning an alignment. A waddle feeling in the back of the vehicle often indicates the occurrence of a bent rim and/or a belt shift in one of the rear tires. Vibration in the steering wheel or in the floor pan is often the result of static imbalance or radial runout of the front tires. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Alignment Inspection > Page 9010 Alignment: Service and Repair Measuring Wheel Alignment Important: This vehicle requires a four wheel alignment. Set the rear wheel alignment angles first to obtain proper front alignment angles. 1. Following the manufacturer's instructions to install alignment equipment. 2. Prior to checking alignment perform the following actions: - Jounce the front bumper 3 times - Jounce the rear bumper 3 times 3. Measure and record the alignment angles. Refer to Wheel Alignment Specifications (Front) or Wheel Alignment Specifications (Rear). Important: When making adjustments to the vehicle set the left side to specifications first. Use the actual readings on the left side as targets for the right side to achieve a minimal cross variance. 4. Make the adjustments that are necessary. 5. Check toe AFTER changing Camber. 6. Check for damaged suspension members if proper specifications cannot be obtained. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Alignment Inspection > Page 9011 Alignment: Service and Repair Front Wheel Alignment Front Camber Adjustment Removal Procedure 1. Raise the vehicle and provide suitable support. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies from the front and the rear axles. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Remove the strut from the vehicle. Refer to Strut Assembly Replacement in Steering and Suspension. 4. Place the strut in a vise and file the hole lateral (oblong). Compare the appearance of the holes before filing (2) with after filing (3): Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the strut to the vehicle. Refer to Strut Assembly Replacement in Steering and Suspension. Tighten the strut-to-knuckle bolts as far as to allow movement of the knuckle. 2. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Adjust the camber (1). Tighten the strut-to-knuckle bolts to 122 Nm (90 ft. lbs.) Lower the vehicle. Front Wheel Toe Adjustment 1. Perform the following steps to remove the small seal clamp: 2. Position the steering wheel in the straight ahead position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Alignment Inspection > Page 9012 3. Loosen the hex nut on the tie rod (2). Turn the tie rod shaft (1) in order to obtain the proper toe angle. Refer to Wheel Alignment Specifications (Front) or Wheel Alignment Specifications (Rear). 4. Confirm the number of threads showing on each tie rod end is nearly equal. Notice: Refer to Fastener Notice in Service Precautions. 5. Confirm that the tie rod ends (3) are square before you tighten the lock nuts (2). Tighten the hex nuts at the tie rod ends to 68 Nm (50 ft. lbs.). Important: Ensure the seals do not twist. 6. Install the seal clamps. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Alignment Inspection > Page 9013 Alignment: Service and Repair Preliminary Alignment Inspection Loose and worn suspension parts prevents an accurate setting of alignment angles. Before you make any alignment adjustments, ensure the correctness of the alignment readings and the adjustments: Check the tires for proper inflation pressures. Refer to Tire Inflation Pressure Specifications. - Check the tires for normal tread wear. - Check the hub and bearing for excessive wear. - Check the ball joints and the tie rods for looseness. - Inspect the wheels and tires for runout, resulting from bent wheels or faulty tires. - Inspect vehicle trim heights. If the trim heights are not within specifications, make necessary corrections before adjusting the alignment. Refer to Trim Height Specifications in Suspension General Diagnosis. - Check the steering gear for looseness at the frame. - Check the struts for improper operation. - Inspect the control arms for loose or worn bushings. - Check the stabilizer shaft attachments for loose or missing components. - Check the alignment pins for improper frame alignment to the body. - Check the frame fasteners for proper torque. - Check the frame insulators for wear or damage. Before checking the alignment, become familiar with the instructions that are furnished by the equipment manufacturer. Methods will vary with different equipment. Regardless of the equipment used for adjusting the alignment, always keep the vehicle on a level surface, both fore-and-aft and sideways. Important: - Check and set the alignment with a full fuel tank. - Jounce the vehicle three times before you check the alignment in order to eliminate false readings. - Hold the front and the rear suspensions to the specified dimensions. Refer to Trim Height Specifications in Suspension General Diagnosis. - Set the toe left side adjustment and the toe right side adjustment separately per wheel. Hold the steering wheel level at O degrees plus or minus 3.5 degrees. Cross caster within 0.75 degrees. - Cross camber within 0.75 degrees. Adjust Perform four wheel alignment adjustments in the following order: 1. Rear wheel camber 2. Rear wheel toe and tracking 3. Front wheel camber 4. Front wheel toe and steering wheel angle Pre-Alignment Road Test With Customer Perform a road test on the vehicle with the customer. The road test may help to identify many faulty parts: - Worn control arm bushings or strut bearings - Weak strut dampeners - Loose power steering gear mounts - Wheel bearings - Tires Obvious conditions must be brought to the customer's attention before beginning an alignment. A waddle feeling in the back of the vehicle often indicates the occurrence of a bent rim and/or a belt shift in one of the rear tires. Vibration in the steering wheel or in the floor pan is often the result of static imbalance or radial runout of the front tires. Measuring Wheel Alignment Important: This vehicle requires a four wheel alignment. Set the rear wheel alignment angles first to obtain proper front alignment angles. 1. Following the manufacturer's instructions to install alignment equipment. 2. Prior to checking alignment perform the following actions: - Jounce the front bumper 3 times - Jounce the rear bumper 3 times 3. Measure and record the alignment angles. Refer to Wheel Alignment Specifications (Front) or Wheel Alignment Specifications (Rear). Important: When making adjustments to the vehicle set the left side to specifications first. Use the actual readings on the left side as targets for the right side to achieve a minimal cross variance. 4. Make the adjustments that are necessary. 5. Check toe AFTER changing Camber. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Alignment Inspection > Page 9014 6. Check for damaged suspension members if proper specifications cannot be obtained. Front Camber Adjustment Removal Procedure 1. Raise the vehicle and provide suitable support. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies from the front and the rear axles. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Remove the strut from the vehicle. Refer to Strut Assembly Replacement in Steering and Suspension. 4. Place the strut in a vise and file the hole lateral (oblong). Compare the appearance of the holes before filing (2) with after filing (3): Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the strut to the vehicle. Refer to Strut Assembly Replacement in Steering and Suspension. Tighten the strut-to-knuckle bolts as far as to allow movement of the knuckle. 2. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Adjust the camber (1). Tighten the strut-to-knuckle bolts to 122 Nm (90 ft. lbs.) Lower the vehicle. Front Wheel Toe Adjustment 1. Perform the following steps to remove the small seal clamp: 2. Position the steering wheel in the straight ahead position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Alignment Inspection > Page 9015 3. Loosen the hex nut on the tie rod (2). Turn the tie rod shaft (1) in order to obtain the proper toe angle. Refer to Wheel Alignment Specifications (Front) or Wheel Alignment Specifications (Rear). 4. Confirm the number of threads showing on each tie rod end is nearly equal. Notice: Refer to Fastener Notice in Service Precautions. 5. Confirm that the tie rod ends (3) are square before you tighten the lock nuts (2). Tighten the hex nuts at the tie rod ends to 68 Nm (50 ft. lbs.). Important: Ensure the seals do not twist. 6. Install the seal clamps. Rear Camber Adjustment Removal Procedure 1. Raise the vehicle and provide suitable support. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Remove the strut from the vehicle. Refer to Strut Assembly Replacement in Rear Suspension. 4. Place the strut in a vise and file the upper strut-to-knuckle hole lateral (oblong). Compare the appearance of the holes before filing (2) with after filing (3). Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the strut to the vehicle. Refer to Strut Assembly Replacement in Rear Suspension. Tighten the strut-to-knuckle bolts as far as to allow movement of the knuckle. 2. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Alignment Inspection > Page 9016 3. Adjust the camber (1). Tighten the strut-to-knuckle bolts to 122 Nm (90 ft. lbs.) 4. Lower the vehicle. Rear Toe Adjustment 1. Loosen the hex nuts at the rear wheel spindle rod (rear). 2. Turn the adjusting nut to change the toe angle. 3. Adjust the toe to the proper setting. Refer to Wheel Alignment Specifications (Front) or Wheel Alignment Specifications (Rear). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Alignment Inspection > Page 9017 4. Tighten the hex nuts on the rear wheel spindle rod (rear). Tighten the rear wheel spindle rod ends hex nuts to 50 Nm (37 ft. lbs.). Alignment Rack Maintenance Adjust the rack for level and for calibration according to the manufacturer's recommended intervals. Refer to the alignment rack manufacturer's operators guide for information regarding the adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation The front knuckle is a machined aluminum casting. Do not use a hammer in order to loosen suspension components from the knuckle. Suspension components which are attached to the knuckle are made of steel. The following components have special coatings which prevent corrosion: - The front lower control arm ball stud - The ABS sensor bracket - The strut damper Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation > Page 9034 Front Steering Knuckle: Service and Repair Removal Procedure Tools Required J 41820 Ball Joint/Stud Separator - J 24319-B Universal Steering Linkage Puller 1. Raise and suitably support the vehicle. 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation. 3. Remove the front wheel drive shaft bearing. Refer to Front Wheel Drive Shaft Bearing Replacement. 4. Remove the front lower control arm ball stud-to-knuckle cotter pin and nut. 5. Separate the front lower control arm stud from the front steering knuckle using the J 41820 Ball Joint/Stud Separator. 6. Remove the outer tie rod end from the steering knuckle. Use the J 24319-B. 7. Scribe the strut to the knuckle. 8. Remove the bolts connecting the strut to the knuckle. 9. Remove the knuckle from the vehicle. Installation Procedure 1. Install the knuckle to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts which connect the strut to the knuckle. Tighten the strut to knuckle bolts to 122 Nm (90 ft. lbs.). 3. Install the outer tie rod to the steering knuckle. 4. Connect the front lower control arm ball stud to knuckle and install the front lower control arm ball stud nut. Tighten the front lower control arm ball stud to knuckle nut to 20 Nm + 120° (15 ft. lbs. + 120°). Align the slots to the front lower control arm ball stud nut with a cotter pin hole by tightening the nut. Do NOT loosen the nut in order to align the holes for the cotter pin. 5. Install the front lower control arm ball stud cotter pin. 6. Install the front wheel drive shaft bearing. Refer to Front Wheel Drive Shaft Bearing Replacement. 7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Tools Required J 35555 Mity Vac - J 43485 Power Steering Bleeder Adapter Important: Hoses touching the frame, body, or engine may cause system noise. 1. Verify that the hoses do not touch any other part of the vehicle. Important: Loose connections may not leak, but could allow air into the steering system. 2. Verify that all hose connections are tight. Important: Maintain the fluid level throughout the bleed procedure. 3. Remove the pump reservoir cap. Notice: If the power steering system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from the steering system. The air in the fluid may cause pump cavitation noise and may cause pump damage over a period of time. Notice: When adding fluid or making a complete fluid change, always use the proper power steering fluid. Failure to use the proper fluid will cause hose and seal damage and fluid leaks. Important: Use clean, new power steering fluid only. 4. Fill the pump reservoir with fluid to the FULL COLD level. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 9039 5. Attach the J 43485 to the J 35555 or equivalent. 6. Place the J 43485 on or in the pump reservoir filler neck. 7. Apply a vacuum of 68 kPa (20 inch lbs.) maximum. 8. Wait 5 minutes. Typical vacuum drop is 7-10 kPa (2-3 inch lbs.). If the vacuum does not remain steady, refer to Excessive Vacuum Drop Diagnosis at the end of this procedure. 9. Remove the J 43485 and the J 35555. 10. Reinstall the pump reservoir cap. 11. Start the engine. Allow the engine to idle. 12. Turn off the engine. 13. Verify the fluid level. Repeat steps 11-13 until the fluid stabilizes. Important: Do not turn steering wheel to lock. 14. Start the engine. Allow the engine to idle. 15. Turn the steering wheel 180-360 degrees in both directions 5 times. 16. Switch the ignition off. 17. Verify the fluid level. 18. Remove the pump reservoir cap. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 9040 19. Attach the J 43485 to the J 35555 or equivalent. 20. Place the J 43485 on or in the pump reservoir filler neck. 21. Apply a vacuum of 68 kPa (20 inch lbs.) maximum. 22. Wait 5 minutes. 23. Remove the J 43485 and the J 35555. 24. Verify the fluid level. 25. Reinstall the pump reservoir cap. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Noise Diagnostics TSB References Power Steering Fluid: Technical Service Bulletins Steering - Noise Diagnostics TSB References INFORMATION Bulletin No.: 06-02-32-009B Date: November 19, 2008 Subject: Overview of Steering System Noises Models: 2001-2004 Buick Regal 2001-2005 Buick Century 2005-2007 Buick Allure (Canada Only), LaCrosse 2000-2006 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo 1998-2002 Oldsmobile Intrigue 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to remove reference to Corporate Bulletin Number 01-02-32-001 from the table below. Please discard Corporate Bulletin Number 06-02-32-009A (Section 02 - Steering). The purpose of this bulletin is to provide a quick reference for dealers to aid in locating the correct service bulletin for several different steering system noise concerns. Many customer concerns with the steering system involve specific symptoms (noises heard). Once the customer concern has been verified, the table above may help identify the correct bulletin to reference. If other symptoms are present, or if diagnosis indicates another cause not found in any of the three service bulletins, refer to SI to diagnose the repair customer concern. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Complete system 1.5 pt (US) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 9047 Power Steering Fluid: Fluid Type Specifications x x Power Steering Fluid GM Power Steering Fluid (GM P/N 1050017 - 1 quart or Equivalent) Cold Climate Power Steering Fluid 12345866 or Equivalent Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair Power Steering Fluid Reservoir: Service and Repair Disassembly Procedure 1. Place the hydraulic pump (1) on a fixed, flat surface, with the shaft facing upward. 2. Insert a screwdriver into the retaining clip tab (3). 3. Using the screwdriver, force the retaining clip tab (3) outward. 4. Slide the reservoir clip (4) away from the hydraulic pump assembly (1). 5. Repeat the above steps to remove the second reservoir clip (4). 6. Remove the reservoir (2) from the hydraulic pump housing (1). 7. Remove the O-ring seal from the neck of the reservoir (2) or the hydraulic pump housing (1). Discard the O-ring seal. Assembly Procedure 1. Lubricate the new O-ring seal with power steering fluid. 2. Install the new O-ring seal onto the neck of the reservoir (2). 3. Install the reservoir (2) onto the hydraulic pump assembly (1). Ensure the reservoir neck is completely engaged onto the hydraulic pump assembly (1). 4. Align the feet of the reservoir with the sides of the hydraulic pump housing. 5. Install the new reservoir retaining clips (4) (supplied with the pump). Ensure the retaining clip tabs (3) fully engage with the hydraulic pump housing (1). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Fastener Tightening Specifications Power Steering Line/Hose: Specifications Power Steering Cooler Pipe Bolt 84 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Fastener Tightening Specifications > Page 9055 Power Steering Line/Hose: Specifications Power Steering Return Hose Clamp Fitting to Power Steering Pump 20 ft.lb Power Steering Pressure Line Fitting to Power Steering Gear 20 ft.lb Power Steering Pressure Line Fitting to Power Steering Pump 20 ft.lb Power Steering Return Line Fitting to Power Steering Gear 20 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hoses Replacement Power Steering Line/Hose: Service and Repair Power Steering Hoses Replacement Removal Procedure 1. Place a drain pan under the vehicle. 2. Remove the clamps from the power steering return line to the power steering pump. 3. Remove the rubber section of hose that connects the power steering return line to the power steering pump. 4. Remove the rubber section of the power steering return line from the vehicle. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the clamps from the power steering return line and the power steering cooler pipe. 7. Remove the rubber section of hose that connects the power steering return line to the power steering cooler pipe. 8. Remove the rubber section of the power steering return line from the vehicle. Installation Procedure 1. Position the rubber section of the power steering return line to the vehicle. 2. Install the rubber section of hose that connects the power steering return line to the power steering cooler pipe. 3. Install the clamps to the power steering return line and the power steering cooler pipe. 4. Lower the vehicle. 5. Position the rubber section of the power steering return line to the vehicle. 6. Install the rubber section of hose that connects the power steering return line to the power steering pump. 7. Install the clamps to the rubber section of hose that connects the power steering return line to the power steering pump. 8. Remove the drain pan from under the vehicle. 9. Fill the power steering system. Refer to Refilling the Power Steering System. 10. Bleed the power steering system. Refer to Bleeding the Power Steering System. 11. Inspect the power steering system for leaks. Refer to Steering and Suspension Leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hoses Replacement > Page 9058 Power Steering Line/Hose: Service and Repair P/S Cooler Pipe/Hose Replacement Removal Procedure 1. Remove the engine mount struts from the engine. Refer to Engine Mount Strut Replacement (Left) and Engine Mount Strut Replacement (Right) in Engine. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 4. Place a drain pan under the vehicle. Notice: The front wheels of the vehicle must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. Failure to follow these procedures will cause improper alignment of some components during installation and result in damage to the SIR coil assembly. 5. Remove the intermediate steering shaft from the power steering gear stub shaft. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column - Tilt. 6. Use a utility stand in order to support the frame. 7. Remove the frame bolts from the rear of the frame. Refer to Frame Removal in Frame and Underbody. Notice: Do not lower the rear of the frame too far as damage to the engine components nearest to the cowl may result. 8. Use the utility stand in order to lower the rear of the frame to gain access. 9. Remove the power steering return hose from the power steering pump to the power steering cooler pipe. 10. Remove the power steering return line from the power steering gear. 11. Remove the power steering return line from the clamp on the power steering gear. 12. Remove the power steering cooler pipe retaining clips. 13. Remove the power steering cooler pipe from the vehicle. Installation Procedure 1. Install the power steering cooler pipe to the vehicle. 2. Install the power steering cooler pipe retaining clips. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hoses Replacement > Page 9059 3. Install the power steering return line to the power steering gear. Refer to Power Steering Return Hose Replacement. 4. Install the power steering return line to the clamp on the power steering gear. 5. Install the power steering return hose from the power steering pump to the power steering cooler pipe. 6. Use the utility stand in order to raise the frame. 7. Install NEW frame bolts to the rear of the frame. Refer to Frame Removal in Frame and Underbody. 8. Install the intermediate steering shaft to the power steering gear stub shaft. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column-Tilt. 9. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 10. Remove the drain pan from under the vehicle. 11. Lower the vehicle. 12. Install the engine mount struts to the engine. Refer to Engine Mount Strut Replacement (Left) and Engine Mount Strut Replacement (Right) in Engine. 13. Fill the power steering fluid reservoir. Refer to Refilling the Power Steering System. 14. Bleed the power steering system. Refer to Bleeding the Power Steering System. 15. Inspect the power steering system for leaks. Refer to Steering and Suspension Leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hoses Replacement > Page 9060 Power Steering Line/Hose: Service and Repair P/S Pressure Hose Replacement Removal Procedure 1. Place a drain pan under the vehicle. 2. Remove the power steering pressure line from the power steering pump. 3. Remove the power steering pressure line from the power steering lines retaining bracket on the engine. 4. Remove the power steering line from the power steering gear performing the following steps: 4.1. The power steering pressure line is the lower line at the power steering gear. 4.2. Using a 18 mm (crow's foot line wrench with a 2 foot long, 3/8 inch drive extension). 4.3. Access the line from the engine compartment, between the rocker arm cover and the front of the dash mat. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hoses Replacement > Page 9061 6. Remove the power steering pressure line (1) from the clamps on the power steering gear. 7. Remove the power steering pressure line (1) from the vehicle. Installation Procedure 1. Install the power steering pressure line (1) to the vehicle. 2. Install the power steering pressure line (1) to the clamps on the power steering gear. 3. Lower the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the power steering pressure line to the power steering gear. Use a 18 mm crow's foot line wrench with a 2 foot long, 3/8 inch drive extension. Tighten the power steering pressure line fitting to the power steering gear to 27 Nm (20 ft. lbs.). 5. Install the power steering pressure line to the power steering lines retaining bracket on the engine. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hoses Replacement > Page 9062 6. Install the power steering pressure line to the power steering pump. Tighten the power steering pressure line fitting to the power steering pump to 27 Nm (20 ft. lbs.). 7. Fill the power steering system with power steering fluid. Refer to Refilling the Power Steering System. 8. Bleed the power steering system. Refer to Bleeding the Power Steering System. 9. Inspect the power steering system for leaks. Refer to Steering and Suspension Leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hoses Replacement > Page 9063 Power Steering Line/Hose: Service and Repair P/S Return Line Replacement Removal Procedure 1. Place a drain pan under the vehicle in order to catch any draining power steering fluid. 2. Remove the power steering return hose from the power steering pump. 3. Remove the power steering return hose from the power steering lines retaining bracket on the engine. 4. Remove the power steering return hose from the power steering cooler pipe. 5. Remove the power steering return hose from the vehicle. Installation Procedure 1. Install the power steering return hose. 2. Install the power steering return hose to the power steering cooler pipe. 3. Install the power steering return hose to the power steering lines retaining bracket on the engine. 4. Install the power steering return hose to the power steering pump. 5. Fill the power steering system. Refer to Refilling the Power Steering System 6. Bleed the power steering system. Refer to Bleeding the Power Steering System 7. Inspect the power steering system for leaks. Refer to Steering and Suspension Leaks 8. Remove the drain pan from under the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > Steering - Power Steering Pump Replacement Tips Power Steering Motor: Technical Service Bulletins Steering - Power Steering Pump Replacement Tips INFORMATION Bulletin No.: 06-02-32-013B Date: August 07, 2009 Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is Necessary Models: 1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and update the information. Please discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering). A recently completed analysis of returned power steering (PS) pumps that had been replaced for noise, no power assist, no or low pressure and leaking conditions has indicated a high number of "No Trouble Found" results. Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering concern, the steering system analyzer should be utilized to assist the technician in a successful diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer. In addition, extensive warranty analysis has shown that the following situations are all significant root causes of PS pump failures: - Improper pulley installation - Re-using the O-rings - Using fluid other than the OE-specified steering fluid - Failure to flush the PS system In order to help improve customer satisfaction and reduce comebacks, GM recommends the following tips for replacing a PS pump: 1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which could cause the pressure relief valve to stop functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will result in pump failure. 2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical, distorting the pulley may damage bearings on the new PS pump. Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. 3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must be lubricated with OE-specific PS fluid prior to installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT covering the pressure bypass hole. 4. Bleed the PS system according to the procedures/recommendations in SI. Following these procedures and using the correct tools and fluids should help ensure that the new PS pump operates properly. Skipping steps may cost you time and trouble later. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Power Steering Pump Flow Control Valve 55 ft.lb Power Steering Pump Mounting Bolts 25 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 9072 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Valve Closed ....................................................................................................................................... ..................................................................... 1000 psi Valve Open ..................................................... .................................................................................................................................................... 80 125 psi Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 9073 Power Steering Pump: Capacity Specifications Pump Only ........................................................................................................................................... ..................................................................... 1.0 pints Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 9074 Power Steering Pump: Diagrams Power Steering Pump Assembly-CB Series Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 9075 Power Steering Pump: Description and Operation The power steering pump is a vane-type pump which provides hydraulic pressure for the system. The power steering system consists of the following components: - The driveshaft - The pump housing - The pump ring - The pressure plate - The thrust plate - The flow control valve - The rotor - The vanes The opening at the rear of the pump housing contains the following components: - The pump ring - The pressure plate - The thrust plate - The rotor - The vanes The end plate The small opening on the side of the housing contains the following components: - The pressure line fitting - The flow control valve - The spring The flow control orifice is a component of the pressure line fitting. A pressure relief valve inside the flow control valve limits the pump pressure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 9076 Power Steering Pump: Testing and Inspection Please see STEERING/TESTING and INSPECTION for information on this component. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Replacement Power Steering Pump: Service and Repair Power Steering Pump Flow Control Valve Replacement Removal Procedure 1. Remove the O-ring union fitting (5) from the hydraulic pump housing assembly (1). 2. Remove the O-ring seal (4) from the O-ring union fitting (5). 3. Remove the control valve assembly (3). 4. Remove the flow control spring (2). Installation Procedure 1. Install the flow control spring (2) to the hydraulic pump housing assembly (1). 2. Install the control valve assembly (3). 3. Lubricate the O-ring seal (4) with power steering fluid. 4. Install the O-ring seal (4) onto the O-ring union fitting (5). Notice: Refer to Fastener Notice in Service Precautions. 5. Install the O-ring union fitting (5) into the hydraulic pump housing assembly (1). Tighten the fitting (5) to 75 Nm (55 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Replacement > Page 9079 Power Steering Pump: Service and Repair Power Steering Pump Replacement Removal Procedure 1. Place a drain pan under the vehicle. 2. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling. 3. Remove the power steering pump pulley from the power steering pump. Refer to Power Steering Pulley Replacement. 4. Remove the ignition wiring harness near the power steering pump. 5. Disconnect the following components from the power steering pump: - The power steering pressure line. Refer to Power Steering Pressure Hose Replacement (3.8 L) or Power Steering Pressure Hose Replacement (3.4 L). - The power steering return hose. Refer to Power Steering Return Hose Replacement (3.4 L) or Power Steering Return Hose Replacement (3.8 L). 6. Remove the power steering pump mounting bolts from the power steering pump. 7. Remove the power steering pump assembly. 8. Remove the power steering pump reservoir from the power steering pump. Refer to Power Steering Reservoir Replacement - Off Vehicle (CB Series). Installation Procedure 1. Install the power steering pump reservoir to the power steering pump. Refer to Power Steering Reservoir Replacement - Off Vehicle (CB Series). 2. Position the power steering pump assembly to the engine. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the power steering pump mounting bolts. Tighten the power steering pump mounting bolts to 34 Nm (25 ft. lbs.). 4. Connect the following components to the power steering pump: - The power steering pressure line. Refer to Power Steering Pressure Hose Replacement (3.8 L) or Power Steering Pressure Hose Replacement (3.4 L). - The power steering return hose. Refer to Power Steering Return Hose Replacement (3.4 L) or Power Steering Return Hose Replacement (3.8 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Replacement > Page 9080 L). 5. Install the ignition control wiring harness at the power steering pump. 6. Install the power steering pump pulley to the power steering pump. Refer to Power Steering Pulley Replacement. 7. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling. 8. Fill the power steering system. Refer to Refilling the Power Steering System. 9. Bleed the power steering system. Refer to Bleeding the Power Steering System. 10. Inspect the system for leaks. Refer to Steering and Suspension Leaks. 11. Remove the drain pan from under the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Replacement > Page 9081 Power Steering Pump: Service and Repair Pulley Removal and Installation Removal Procedure Tools Required J 25033-C Power Steering Pump Pulley Installer - J 25034-C Power Steering Pump Pulley Remover 1. Remove the power steering pump assembly from the vehicle. Refer to Power Steering Pump Replacement. 2. Using the J 25034-C Remove the power steering pump pulley from the power steering pump. Installation Procedure Important: Never use a hammer to install the power steering pulley. - Do not use an arbor press to install the power steering pulley. - The face of the pulley hub must be flush with the end of the pump driveshaft. 1. Using the J 25033-C Install the power steering pump pulley to the power steering pump. 2. Install the power steering pump assembly to the vehicle. Refer to Power Steering Pump Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions CAUTION: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserve energy supply. The reserve energy supply provides deployment power for the air bags. Deployment power is available for as much as 10 seconds after disconnecting the vehicle power by any of the following methods: ^ Turn OFF the ignition. ^ Remove the fuse that provides power to the SDM. ^ Disconnect the vehicle battery from the vehicle electrical system. Disabling the SIR system prevents deploying of the air bags from the reserve energy supply power. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the LH instrument panel access hole cover. 5. Remove the SDM Fuse from the fuse block. IMPORTANT: With the SDM Fuse removed and the ignition ON, The AIR BAG warning lamp illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the RH instrument panel access hole cover. 7. Unclip the frontal air bags yellow 4-way connector from the metal rail. 8. Remove the Connector Position Assurance (CPA) from the frontal air bags yellow 4-way connector. 9. Disconnect the frontal air bags yellow 4-way connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 9088 10. Remove the connector position assurance (CPA) from the driver side air bag yellow 2-way connector (4) located under the driver seat, if the vehicle is equipped with a driver side air bag. 11. Disconnect the driver side air bag yellow 2-way connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 9089 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Connect the driver side air bag yellow 2-way connector (4) located under the driver seat, if the vehicle is equipped with a driver side air bag. 2. Install the CPA to the driver side air bag yellow 2-way connector. 3. Connect the frontal air bags yellow 4-way connector located at the RH side of the instrument panel. 4. Install the CPA to the frontal air bags yellow 4-way connector. 5. Connect the frontal air bags yellow 4-way connector to the metal rail. 6. Instal the RH instrument panel access hole cover. 7. Install the SDM fuse to the LH fuse block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 9090 8. Install the LH instrument panel access hole cover. 9. Staying well away from the airbags, turn ON the ignition. 9.1. The AIR BAG warning lamp will flash seven times. 9.2. The AIR BAG warning lamp will then turn OFF. 10. Perform A Diagnostic System Check SIR if the AIR BAG warning lamp does not operate as described. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Pinion Shaft > Component Information > Technical Service Bulletins > Steering - Noise Diagnostics TSB References Steering Gear Pinion Shaft: Technical Service Bulletins Steering - Noise Diagnostics TSB References INFORMATION Bulletin No.: 06-02-32-009B Date: November 19, 2008 Subject: Overview of Steering System Noises Models: 2001-2004 Buick Regal 2001-2005 Buick Century 2005-2007 Buick Allure (Canada Only), LaCrosse 2000-2006 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo 1998-2002 Oldsmobile Intrigue 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to remove reference to Corporate Bulletin Number 01-02-32-001 from the table below. Please discard Corporate Bulletin Number 06-02-32-009A (Section 02 - Steering). The purpose of this bulletin is to provide a quick reference for dealers to aid in locating the correct service bulletin for several different steering system noise concerns. Many customer concerns with the steering system involve specific symptoms (noises heard). Once the customer concern has been verified, the table above may help identify the correct bulletin to reference. If other symptoms are present, or if diagnosis indicates another cause not found in any of the three service bulletins, refer to SI to diagnose the repair customer concern. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 01-02-32-001P > Nov > 09 > Steering - Steering Column Clunking When Turning Steering Shaft: Customer Interest Steering - Steering Column Clunking When Turning TECHNICAL Bulletin No.: 01-02-32-001P Date: November 25, 2009 Subject: Clunk Felt/Noise Heard From Steering Column, Steering Gear and/or Front Of Vehicle During Turning Maneuver and/or Steering Wheel Rotation (Replace Intermediate Shaft As Directed) Models: 2001-2004 Buick Regal 2005-2008 Buick Allure (Canada Only), LaCrosse 2000-2008 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo 1998-2002 Oldsmobile Intrigue 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to add the 2008 Buick LaCrosse/Allure. Please discard Corporate Bulletin Number 01-02-32-001O (Section 02 - Steering). Condition Some customers may comment on a clunk type noise coming from the front of the vehicle while driving during a turning maneuver. This condition may also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Some vehicles may only exhibit the noise once for every 360° of wheel rotation. On all other vehicles, this clunk noise will be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel or when applying/releasing the brakes. Cause This condition may be caused by a "slip stick" condition of the steering intermediate shaft resulting in the clunk noise or feel through the steering wheel. Diagnostic Tip Important This condition is commonly misdiagnosed as originating in the steering gear and has resulted in the replacement of numerous steering gears without correcting the concern. Attempt to duplicate the customer's concern and isolate the I-shaft by following the procedure below: 1. Locate a large area (parking lot) where the vehicle can be turned in a tight circle. 2. Turn the steering wheel to the right and/or left all the way to the steering lock, then off the steering lock a 1/4 turn. 3. Drive the vehicle approximately 5 km/h (3 mph) in a circle, preferably over rough pavement or seams on the road surface. 4. Drive the vehicle straight ahead at idle speed while applying and releasing the brake pedal. Listen/feel the steering wheel for the clunk/noise condition. 5. If a clunk is felt in the steering wheel, the MOST likely cause is the I-shaft - not the steering gear. Continue with the correction. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 01-02-32-001P > Nov > 09 > Steering - Steering Column Clunking When Turning > Page 9104 Correction Replace the existing intermediate shaft using the service procedure found in Service Information. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-02-32-001P > Nov > 09 > Steering - Steering Column Clunking When Turning Steering Shaft: All Technical Service Bulletins Steering - Steering Column Clunking When Turning TECHNICAL Bulletin No.: 01-02-32-001P Date: November 25, 2009 Subject: Clunk Felt/Noise Heard From Steering Column, Steering Gear and/or Front Of Vehicle During Turning Maneuver and/or Steering Wheel Rotation (Replace Intermediate Shaft As Directed) Models: 2001-2004 Buick Regal 2005-2008 Buick Allure (Canada Only), LaCrosse 2000-2008 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo 1998-2002 Oldsmobile Intrigue 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to add the 2008 Buick LaCrosse/Allure. Please discard Corporate Bulletin Number 01-02-32-001O (Section 02 - Steering). Condition Some customers may comment on a clunk type noise coming from the front of the vehicle while driving during a turning maneuver. This condition may also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Some vehicles may only exhibit the noise once for every 360° of wheel rotation. On all other vehicles, this clunk noise will be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel or when applying/releasing the brakes. Cause This condition may be caused by a "slip stick" condition of the steering intermediate shaft resulting in the clunk noise or feel through the steering wheel. Diagnostic Tip Important This condition is commonly misdiagnosed as originating in the steering gear and has resulted in the replacement of numerous steering gears without correcting the concern. Attempt to duplicate the customer's concern and isolate the I-shaft by following the procedure below: 1. Locate a large area (parking lot) where the vehicle can be turned in a tight circle. 2. Turn the steering wheel to the right and/or left all the way to the steering lock, then off the steering lock a 1/4 turn. 3. Drive the vehicle approximately 5 km/h (3 mph) in a circle, preferably over rough pavement or seams on the road surface. 4. Drive the vehicle straight ahead at idle speed while applying and releasing the brake pedal. Listen/feel the steering wheel for the clunk/noise condition. 5. If a clunk is felt in the steering wheel, the MOST likely cause is the I-shaft - not the steering gear. Continue with the correction. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-02-32-001P > Nov > 09 > Steering - Steering Column Clunking When Turning > Page 9110 Correction Replace the existing intermediate shaft using the service procedure found in Service Information. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9116 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9117 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9118 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9124 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9125 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9126 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Page 9127 Steering Shaft: Service and Repair Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment 3. Position the intermediate steering shaft seal in order to provide access to the intermediate steering shaft lower pinch bolt. 4. Remove the intermediate steering shaft lower pinch bolt from the power steering gear stub shaft (2). Notice: The front wheels of the vehicle must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. Failure to follow these procedures will cause improper alignment of some components during installation and result in damage to the SIR coil assembly. 5. Remove the intermediate steering shaft (1) from the power steering gear stub shaft (2). 6. Lower the vehicle. 7. Remove the left instrument panel insulator. Refer to Insulator Replacement - IP (Left) or Insulator Replacement - IP (Right) in Instrument Panel, Gauges and Warning Indicators Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Page 9128 8. Reposition the intermediate steering shaft seal in order to gain access to the intermediate steering shaft upper pinch bolt. 9. Remove the intermediate steering shaft upper pinch bolt. 10. Disconnect the intermediate steering shaft from the steering column. 11. Remove the intermediate steering shaft. Installation Procedure 1. Position the intermediate steering shaft into place. Notice: Refer to Fastener Notice in Service Precautions 2. Install the intermediate steering shaft upper pinch bolt at the steering column. Tighten the intermediate steering shaft upper pinch bolt to 48 Nm (35 ft. lbs.). 3. Install the intermediate steering shaft seal onto the steering column. 4. Raise and support the vehicle. Refer to Vehicle Lifting 5. Install the intermediate steering shaft (1) to the power steering gear stub shaft (2). 6. Install the intermediate steering shaft lower pinch bolt at the power steering gear stub shaft. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Page 9129 Tighten the intermediate steering shaft lower pinch bolt to 48 Nm (35 ft. lbs.). 7. Install the intermediate steering shaft seal onto the power steering gear. 8. Install the Tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 9. Lower the vehicle. 10. Install the left instrument panel insulator. Refer to Insulator Replacement - IP (Left) or Insulator Replacement - IS (Right) in Instrument Panel, Gauges and Warning Indicators Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations > Steering Wheel Cruise Control Switches Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations > Steering Wheel Cruise Control Switches > Page 9134 Steering Wheel: Locations Steering Wheel Radio Control Switches Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations > Steering Wheel Cruise Control Switches > Page 9135 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions Steering Wheel: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9138 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9139 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9140 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9141 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9142 Steering Wheel: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9143 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9144 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9145 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9146 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9147 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9148 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9149 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9150 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9151 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9152 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9153 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9154 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9155 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9156 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9157 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9158 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9159 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9160 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9161 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9162 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9163 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Diagram Information and Instructions > Page 9164 Steering Wheel Controls Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Description and Operation > Steering Wheel Controls System Operation Steering Wheel: Description and Operation Steering Wheel Controls System Operation AUDIO STEERING WHEEL CONTROLS (IF EQUIPPED) If your vehicle has this feature, you can control certain radio functions using the buttons on your steering wheel. SEEK: Press the up arrow to tune to the next radio station and the down arrow to tune to the previous radio stations If a cassette tape or compact disc is playing, the player will advance with the up arrow and reverse with the down arrow. PRESET: Press this button to play a station you have programmed on the radio preset buttons. AM-FM: Press this button to choose AM, FM1 or FM2. If a cassette tape or compact disc is playing, it will stop and the radio will play. VOLUME: Press the up or down arrow to increase or decrease volume. PLAY: Press this button to play a cassette tape or compact disc when the radio is playing. MUTE: Press this button to silence the system. Press it again to turn on the sound. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Description and Operation > Steering Wheel Controls System Operation > Page 9167 Steering Wheel: Description and Operation Steering Wheel Controls System Circuit Description STEERING WHEEL CONTROLS The RH steering wheel control switch controls volume, mute, mode and receives power from the positive voltage circuit. The LH steering wheel control switch controls station frequency, scan and preset. When one of the steering wheel control switches is pressed to the desired function, a network of series resistors allows a different voltage output through the remote user interface circuit to the radio. INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL The inflatable restraint steering wheel module coil contains two wires used by the steering wheel control switch. This allows voltage to be applied by the steering wheel control switch to the radio while the steering wheel is being turned. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel Replacement Steering Wheel: Service and Repair Steering Wheel Replacement Removal Procedure Tools Required J 1859-A Steering Wheel Puller - J 42578 Steering Wheel Puller Legs 1. Disable the SIR system. Refer to Disabling the SIR System in Air Bags and Seat Belts 2. Position the ignition to the OFF position. 3. Remove the Inflatable restraint steering wheel module. Refer to Inflatable Restraint Steering Wheel Module Replacement in Air Bags and Seat Belts 4. Scribe an alignment mark on the steering wheel hub. Align the mark with the slash mark on the steering shaft. 5. Loosen the steering wheel nut. 6. Position the nut flush with the end of the steering shaft. 7. Assemble the J 1859-A with the J 42578 on the steering wheel. 8. Using the J 1859-A with the J 42578 Remove the steering wheel from the steering shaft. 9. Remove the J 1859-A with the J 42578 from the steering wheel. 10. Remove the steering shaft nut. 11. Remove the steering wheel from the steering shaft. 12. Unroute the SIR connector from the steering wheel. 13. Remove the steering wheel from the vehicle. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel Replacement > Page 9170 1. Position the steering wheel on the steering column. 2. Route the SIR connector through the steering wheel. 3. Align the scribe mark on the steering wheel with the slash mark on the steering shaft. 4. Install the steering wheel. Notice: Refer to Fastener Notice in Service Precautions 5. Install the steering shaft nut. Tighten the steering shaft nut to 45 Nm (33 ft. lbs.). 6. Install the Inflatable restraint steering wheel module. Refer to Inflatable Restraint Steering Wheel Module Replacement in Air Bags and Seat Belts 7. Enable the SIR system. Refer to Enabling the SIR System in Air Bags and Seat Belts 8. Inspect the operation of the following components: - The horn. - The steering wheel. - The steering wheel controls. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel Replacement > Page 9171 Steering Wheel: Service and Repair Steering Wheel Control Switches Replacement Steering Wheel Control Switches Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System in SIR. 2. Remove the inflatable restraint steering wheel module. 3. Remove the steering wheel. 4. Remove the steering wheel controls wire harness from the retainers in the steering wheel aluminum insert and plastic back shroud. 5. Remove the plastic back shroud screws and the plastic back shroud on the back of the steering wheel. 6. Carefully push on the back of the steering wheel radio control switch through the access opening in the back of the steering wheel switch pocket. 7. Disconnect the electrical connector from the back of the steering wheel radio control switch. 8. Remove the steering wheel radio control switch. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel Replacement > Page 9172 1. Position the steering wheel radio control switch to the steering wheel. Route the radio control wire harness through the access opening in the back of the steering wheel switch pocket. 2. Connect the electrical connector to the back of the steering wheel radio control switch. 3. Carefully install the steering wheel controls switch into the steering wheel switch pocket. IMPORTANT: The steering wheel switch wiring harness must be kept below the white insulators on the back of the steering wheel when installing the plastic back shroud. Do not pinch the wire harness between the steering wheel urethane and the plastic back shroud. 4. Install the plastic back shroud to the back of the steering wheel with the plastic back shroud screws. 5. Install the steering wheel radio controls wiring harness to the retainers in the steering wheel insert and back shroud. Make sure the wiring is not routed underneath any of the four SIR module mounting holes in the steering wheel. 6. Install the plastic back shroud screws and the plastic back shroud on the back of the steering wheel. Tighten Tighten the plastic back shroud screws to 2 N.m (18 lb in). 7. Install the steering wheel. 8. Install the inflatable restraint steering wheel module. 9. Enable the SIR system. Refer to Enabling the SIR System in SIR. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Technical Service Bulletins > Steering - Noise Diagnostics TSB References Tie Rod Boot: Technical Service Bulletins Steering - Noise Diagnostics TSB References INFORMATION Bulletin No.: 06-02-32-009B Date: November 19, 2008 Subject: Overview of Steering System Noises Models: 2001-2004 Buick Regal 2001-2005 Buick Century 2005-2007 Buick Allure (Canada Only), LaCrosse 2000-2006 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo 1998-2002 Oldsmobile Intrigue 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to remove reference to Corporate Bulletin Number 01-02-32-001 from the table below. Please discard Corporate Bulletin Number 06-02-32-009A (Section 02 - Steering). The purpose of this bulletin is to provide a quick reference for dealers to aid in locating the correct service bulletin for several different steering system noise concerns. Many customer concerns with the steering system involve specific symptoms (noises heard). Once the customer concern has been verified, the table above may help identify the correct bulletin to reference. If other symptoms are present, or if diagnosis indicates another cause not found in any of the three service bulletins, refer to SI to diagnose the repair customer concern. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Technical Service Bulletins > Page 9178 Tie Rod Boot: Service and Repair Removal Procedure Tools Required J 22610 Service Boot Clamp Installer 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment 3. Remove the outer tie rod from the inner tie rod assembly. Refer to Tie Rod End Replacement Outer. 4. Remove the inner tie rod jam nut (2) from the inner tie rod assembly (1). 5. Remove the clamp (2) from the end of the inner tie rod boot (1). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Technical Service Bulletins > Page 9179 6. Remove the inner tie rod boot clamp (1) from the inner tie rod boot (3) with side cutters. 7. Discard the inner tie rod boot clamp (1). Important: Prior to removing breather tube (2) or the inner tie rod boot (3), mark the location of the breather tube (2) on the power steering gear assembly. 8. Remove the inner tie rod boot (3) and the breather tube (2). Installation Procedure 1. Install the new inner tie rod boot clamp (1) onto the inner tie rod boot (3). 2. Prior to the inner tie rod boot (3) installation, apply grease to the inner tie rod assembly (2) and the power steering gear assembly (1). 3. Install the inner tie rod boot (3) onto the inner tie rod assembly (2). 4. Align the breather tube with the mark made during removal and the molded nipple of the inner tie rod boot. 5. Install the inner tie rod boot (3) onto the power steering gear assembly until the inner tie rod boot (3) is seated in the power steering gear assembly groove. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Technical Service Bulletins > Page 9180 Important: The inner tie rod boot (3) must not be twisted, puckered or out of shape in any way. If the inner tie rod boot (3) is not shaped properly, adjust the inner tie rod boot (3) by hand before installing the boot clamp. 6. Install the inner tie rod boot (3) onto the inner tie rod assembly (2). 7. Using the J 22610 install the inner tie rod boot clamp (1) on the inner tie rod boot (2) by Firmly crimping the inner tie rod boot clamp (1). 8. Install the inner tie rod small boot clamp (2). 9. Install the inner tie rod jam nut (2) to the inner tie rod assembly (1). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Technical Service Bulletins > Page 9181 10. Install the outer tie rod to the inner tie rod assembly. Refer to Tie Rod End Replacement Outer. 11. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment 12. Lower the vehicle. 13. Perform a front end alignment. Refer to Measuring Wheel Alignment in Wheel Alignment Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - New Outer Tie Rods/Replacement Procedure Tie Rod End: Technical Service Bulletins Steering - New Outer Tie Rods/Replacement Procedure Bulletin No.: 03-02-32-049 Date: October 29, 2003 INFORMATION Subject: Release Of New Outer Tie Rod Ends For Service Models: 1997-2001 Buick Century 1997-2001 Buick Regal 2000-2003 Buick LeSabre, Park Avenue 2002-2003 Buick Rendezvous 1997-2003 Cadillac Seville 2000-2003 Cadillac DeVille 1997-2001 Chevrolet Venture (FWD) 1997-2003 Chevrolet Malibu 2000-2001 Chevrolet Impala, Monte Carlo 2002-2004 Chevrolet Venture (AWD) 1997-2001 Oldsmobile Silhouette (FWD) 1998-2001 Oldsmobile Intrigue 1999-2003 Oldsmobile Alero 2001-2003 Oldsmobile Aurora 2002-2004 Oldsmobile Silhouette (AWD) 1997-2001 Pontiac Grand Prix, Montana (FWD), Trans Sport (FWD) 1999-2003 Pontiac Grand Am 2000-2003 Pontiac Bonneville 2001-2003 Pontiac Aztek 2002-2004 Pontiac Montana (AWD) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - New Outer Tie Rods/Replacement Procedure > Page 9186 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - New Outer Tie Rods/Replacement Procedure > Page 9187 Built Prior to VIN Breakpoint shown. A new outer tie rod end service kit has been released. When replacing the outer tie rod ends, use the improved tie rod end service kit and modify the knuckles. Follow the service procedure below. Procedure Important: DO NOT USE the following outer tie rod end P/N's when servicing the above listed vehicles: ^ 26086579 ^ 26086580 1. Raise and support the vehicle. 2. Remove the front tire and wheel assemblies. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - New Outer Tie Rods/Replacement Procedure > Page 9188 3. Loosen the jam nut (2) on the inner tie rod assembly (1). 4. Remove and discard the prevailing torque nut from the outer tie rod assembly. 5. Using the J 24319-B, remove the outer tie rod assembly (2) from the steering knuckle (1). 6. While removing the outer tie rod end from the inner tie rod assembly, count the number of revolutions it takes to remove the outer tie rod from the inner tie rod and record it. Discard the outer tie rod end. Important: When sanding the knuckle, DO NOT REMOVE excessive material from the knuckle. ONLY USE the emery cloth supplied in the service kit. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - New Outer Tie Rods/Replacement Procedure > Page 9189 7. Use the emery cloth supplied in the service kit to remove the sharp edge on the knuckle shown above. The graphic on the left shows the " before sanding" knuckle and the exploded graphic on the right shows the "after sanded" knuckle. 8. Ensure that the sharp edge and the flashing on the knuckle are removed from the outer tie rod end boot/seal area. 9. Install the new outer tie rod end supplied in the service kit by screwing the outer tie rod end onto the inner tie rod end assembly. Turn the outer tie rod end as many turns as it took to remove the old outer tie rod end from the inner tie rod end assembly. 10. Install the prevailing torque nut to the outer tie rod assembly. Tighten Tighten the prevailing torque nut to 30 N.m (22 lb ft). Tighten the prevailing torque nut an additional 115 degrees of rotation. 11. "Hand Tighten" the jam nut at this time. 12. Install the tire and wheel assembly. 13. Lower the vehicle. 14. Inspect the front toe and adjust if necessary. 15. Tighten the jam nut against the outer tie rod assembly. Tighten Tighten the jam nut to 68 N.m (50 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - New Outer Tie Rods/Replacement Procedure > Page 9190 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - New Outer Tie Rods/Replacement Procedure > Page 9191 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - New Outer Tie Rods/Replacement Procedure > Page 9192 Tie Rod End: Technical Service Bulletins Tie Rod - New Police Vehicle Service Kit File In Section: 02 - Steering Bulletin No.: 02-02-32-006 Date: March, 2002 INFORMATION Subject: New Police Car Tie Rod Service Kit (RPO 9C1 or 9C3) Models: 2000-2001 Chevrolet Impala with RPO 9C1 or 9C3 A new steering outer tie rod assembly was introduced into production at the start of the 2002 model year for police vehicles, RPO 9C1 or 9C3. This new assembly incorporates usage of a new improved seal that is intended to reduce water/contaminate intrusion into the tie rod end. This new assembly has been released for back service usage on 2000 - 2001 model year police cars (RPO 9C1 or 9C3) Notice: Usage of this service part on any other past model vehicle may result in damage to the seal that could lead to premature wear of the tie rod end. For past model vehicles other than police cars, use service kit, P/N 26056811. Parts Information Parts are currently available from GMSPO. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Page 9193 Tie Rod End: Specifications Tie Rod End Nut 22 ft.lb plus 115 degrees Tie Rod End Jam Nut 50 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Page 9194 Tie Rod End: Service and Repair Tools Required J 24319-B Universal Steering Linkage Puller Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Remove the prevailing torque nut (2) from the outer tie rod assembly (1). 4. Loosen the jam nut (2) on the inner tie rod assembly (1). 5. Remove the outer tie rod assembly (1) from the steering knuckle (2) using the special tool J 24319-B Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Page 9195 6. Remove the outer tie rod assembly (3) from the inner tie rod assembly (1). Installation Procedure 1. Install the outer tie rod assembly (3) to the inner tie rod assembly (1). 2. Do not tighten the jam nut (2). 3. Install the outer tie rod assembly (2) to the steering knuckle (1). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Page 9196 4. Install the prevailing torque nut (2) to the outer tie rod assembly (1). Tighten the prevailing torque nut (2) to 30 Nm (22 ft. lbs.). Tighten the prevailing torque nut (2) an additional 120 degrees of rotation. 5. Tighten the jam nut (2) against the outer tie rod assembly (3). Tighten the jam nut against the outer tire rod to 68 Nm (50 ft. lbs.). 6. Install tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 7. Lower the vehicle. 8. Perform a front end alignment. Refer to Measuring Wheel Alignment in Wheel Alignment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications 1. Check the front lower control arm ball stud tightness in the knuckle boss whenever you inspect the front lower control arm ball stud. 2. Raise the vehicle while allowing the front suspension to hang free. 3. Grasp the tire at the top and the bottom. 4. Move the bottom of the tire in an in-and-out motion while checking for movement of the stud end or castellated nut at the knuckle boss. 5. A loose castellated nut may indicate a bent stud or a damaged hole in the knuckle boss. 6. Observe any horizontal movement of the knuckle relative to the control arm. 7. Replace the ball joints/studs if you detect any looseness in the joint or if the ball joint seal is cut. 8. Replace worn or damaged parts with the correct service parts. 9. Failure to use the correct front lower control arm ball stud and specified fastener torque may eventually cause a loose joint. This may result in loss of steering control which could result in personal injury. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 9201 Ball Joint: Testing and Inspection 1. Check the front lower control arm ball stud tightness in the knuckle boss whenever you inspect the front lower control arm ball stud. 2. Raise the vehicle while allowing the front suspension to hang free. 3. Grasp the tire at the top and the bottom. 4. Move the bottom of the tire in an in-and-out motion while checking for movement of the stud end or castellated nut at the knuckle boss. 5. A loose castellated nut may indicate a bent stud or a damaged hole in the knuckle boss. 6. Observe any horizontal movement of the knuckle relative to the control arm. 7. Replace the ball joints/studs if you detect any looseness in the joint or if the ball joint seal is cut. 8. Replace worn or damaged parts with the correct service parts. 9. Failure to use the correct front lower control arm ball stud and specified fastener torque may eventually cause a loose joint. This may result in loss of steering control which could result in personal injury. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 9202 Ball Joint: Service and Repair Removal Procedure 1. Remove the lower control arm. Refer to Lower Control Arm Replacement. 2. Secure the lower control arm in a vice. 3. Drill or grind off the ball stud rivet heads. 4. Use a hammer and a drift punch in order to remove the rivets. 5. Remove the ball stud from the lower control arm. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 9203 1. Install the ball stud to the lower control arm. 2. Install the NEW ball stud bolts facing down, away from the ball stud. Notice: Refer to Fastener Notice in Service Precautions. Important: This is a prevailing torque type fastener. This fastener may be reused ONLY if: - The fastener and its counterpart are clean and free from rust - The fastener develops 2 Nm (18 inch lbs.) of torque (drag) against its counterpart prior to the fastener seating. If the fastener does not meet these criteria, REPLACE the fastener. 3. Install the NEW ball stud nuts. Tighten the NEW ball stud nuts to 68 Nm (50 ft. lbs.). 4. Install the lower control arm. Refer to Lower Control Arm Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension Control Arm Bushing: Service and Repair Front Suspension Removal Procedure Tools Required J 21474-01 Control Arm Bushing Service Set - J 21474-27 Puller Bolt - J 21474 Bushing Installer - J 34126 Driven Sprocket Support Bearing Installer - J 35379 Front Knuckle Support - J 21474-4 Nut 1. Remove the lower control arm. Refer to Lower Control Arm Replacement. 2. Secure the lower control arm in a vice. 3. Mark the lower control arm along the flat edge of the bushing flange. Important: Apply J 23444-A (or equivalent high pressure lubricant) to the threads of the J 21474-27. 4. Assemble the following bushing removal tools as shown: - J 21474-27 - J 41014-1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension > Page 9209 - J 34126 - J 35379 - J 21474-02 - J 21474-4 5. Tighten the J 21474-4 6. Disassemble the bushing removal tools. Installation Procedure Tools Required J 21474-01 Control Arm Bushing Service Set Important: The lower control arm vertical bushing MUST be installed in the same position which it was removed in order to maintain the original vehicle ride, handling and road feel. 1. Align the flat edge of the bushing flange to the mark in the control arm (1). Ensure that the flat edge of the bushing flange is 30 degrees (2) from the centerline of the lower control arm. Ensure that the thin slot in the bushing is facing outboard. 2. Insert the bushing into the control arm. Important: Apply J 23444-A (or equivalent high pressure lubricant) to the threads of the J 21474-27 3. Assemble the following bushing installation tools as shown: 3.1. J 21474-27 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension > Page 9210 3.2. J 41014-1 3.3. J 21474-5 3.4. J 21474-4 Tighten the J 21474-4 5. Disassemble the bushing installation tools. 6. Install the lower control arm. Refer to Lower Control Arm Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension > Page 9211 Control Arm Bushing: Service and Repair Rear Suspension Service the rear (horizontal) control arm bushing with the control arm. You cannot replace this bushing separately. Refer to Lower Control Arm Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair Cross-Member: Service and Repair Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the exhaust pipe. Refer to Exhaust Pipe Replacement (Single Exhaust) or Exhaust Pipe Replacement (Dual Exhaust) in Engine Exhaust. 3. Disconnect the brake lines from the rear suspension support. Refer to Hydraulic Brakes. 4. Disconnect the parking brake cables from the suspension support. Refer to Park Brake Cable Replacement (Front) or Park Brake Cable Replacement (Left/right rear) in Parking Brakes. 5. Disconnect the stabilizer shaft from the rear stabilizer shaft links. 6. Disconnect the stabilizer shaft from the rear suspension support. Important: Support the rear suspension support with jack stands before removing the mounting bolts. 7. Remove the rear suspension support mounting bolts. 8. Disconnect the rear wheel spindle rods from the knuckle. 9. Lower the rear suspension support in order to gain access to the rear wheel spindle rod bolts. 10. Disconnect the rear wheel spindle rods from the rear suspension support. 11. Remove the ABS wiring harness and retainers from the rear suspension support. Remove the rear suspension support. Installation Procedure 1. Position the rear suspension support in place. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the rear wheel spindle rod-to-rear suspension support bolts and nuts. Tighten the rear wheel spindle rod-to-rear suspension support nuts to 140 Nm (103 ft. lbs.). 3. Install the rear suspension support mounting bolts. Tighten the rear suspension support mounting bolts to 105 Nm (77 ft. lbs.). 4. Position the rear wheel spindle rod to the knuckle. Install the retaining bolts and nuts to the knuckle. Tighten the spindle rod-to-knuckle retaining nut to 150 Nm(110 ft. lbs.). 5. Connect the brake lines to the rear suspension support. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Page 9215 6. Install the parking brake cables and the tensioner. Refer to Park Brake Cable Replacement (Front) or Park Brake Cable Replacement (Left/right rear) in Parking Brakes. 7. Install the stabilizer shaft brackets to the rear suspension support. 8. Install the stabilizer shaft bracket bolts to the rear suspension support. Important: Insert the bracket bolts facing rearward. Do not tighten the bolts at this time. 9. Install the stabilizer shaft-to-stabilizer shaft link nuts. Tighten the shaft link nuts to 35 Nm (26 ft. lbs.). 10. Connect the stabilizer shaft to the rear suspension support. 11. Install the stabilizer shaft insulator bracket bolt. Tighten the stabilizer shaft insulator bracket bolts to 48 Nm (35 ft. lbs.). 12. Lower the vehicle. 13. Adjust the rear wheel alignment. Refer to Wheel Alignment Specifications (Front) or Wheel Alignment Specifications (Rear) in Wheel Alignment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation The front knuckle is a machined aluminum casting. Do not use a hammer in order to loosen suspension components from the knuckle. Suspension components which are attached to the knuckle are made of steel. The following components have special coatings which prevent corrosion: - The front lower control arm ball stud - The ABS sensor bracket - The strut damper Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation > Page 9219 Front Steering Knuckle: Service and Repair Removal Procedure Tools Required J 41820 Ball Joint/Stud Separator - J 24319-B Universal Steering Linkage Puller 1. Raise and suitably support the vehicle. 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation. 3. Remove the front wheel drive shaft bearing. Refer to Front Wheel Drive Shaft Bearing Replacement. 4. Remove the front lower control arm ball stud-to-knuckle cotter pin and nut. 5. Separate the front lower control arm stud from the front steering knuckle using the J 41820 Ball Joint/Stud Separator. 6. Remove the outer tie rod end from the steering knuckle. Use the J 24319-B. 7. Scribe the strut to the knuckle. 8. Remove the bolts connecting the strut to the knuckle. 9. Remove the knuckle from the vehicle. Installation Procedure 1. Install the knuckle to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts which connect the strut to the knuckle. Tighten the strut to knuckle bolts to 122 Nm (90 ft. lbs.). 3. Install the outer tie rod to the steering knuckle. 4. Connect the front lower control arm ball stud to knuckle and install the front lower control arm ball stud nut. Tighten the front lower control arm ball stud to knuckle nut to 20 Nm + 120° (15 ft. lbs. + 120°). Align the slots to the front lower control arm ball stud nut with a cotter pin hole by tightening the nut. Do NOT loosen the nut in order to align the holes for the cotter pin. 5. Install the front lower control arm ball stud cotter pin. 6. Install the front wheel drive shaft bearing. Refer to Front Wheel Drive Shaft Bearing Replacement. 7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair Rear Knuckle: Service and Repair Removal Procedure Tools Required J 36660-A Torque Angle Meter 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Disconnect the ABS electrical connector from the wheel speed sensor (1). Refer to Wheel Speed Sensor Replacement (Front) or Wheel Speed Sensor Replacement (Rear) in Antilock Brakes. 4. Remove the brake caliper and bracket. Refer to Brake Caliper Bracket Replacement (Front) or Brake Caliper Bracket Replacement (Rear) in Disc Brakes. 5. Remove the rotor. Refer to Brake Rotor Replacement (Front) or Brake Rotor Replacement (Rear) in Rear Disc Brakes. 6. Remove the rear wheel hub. Refer to Wheel Bearing/Hub Replacement- Rear. 7. Disconnect the rear wheel spindle rods (2) from the knuckle. Refer to Spindle Rod Replacement. 8. Disconnect the trailing arm (3) from the knuckle. Refer to Trailing Arm Replacement. 9. Remove the rear suspension strut to knuckle bolts (1). Refer to Strut Assembly Replacement. 10. Remove the rear suspension knuckle. Installation Procedure 1. Install the rear suspension knuckle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 9223 2. Hand start the rear suspension strut to knuckle bolts (1). Do not tighten the nuts at this time. 3. Connect the rear wheel spindle rods (2) to the knuckle. Refer to Spindle Rod Replacement. 4. Connect the rear suspension trailing arm (3) to the knuckle. Refer to Trailing Arm Replacement. 5. Install the rear wheel hub. Refer to Wheel Bearing/Hub Replacement - Rear. 6. Connect the ABS electrical connector to the wheel speed sensor (1). Refer to Wheel Speed Sensor Replacement (Front) or Wheel Speed Sensor Replacement (Rear) in Antilock Brakes. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the brake caliper and bracket. Refer to Brake Caliper Bracket Replacement (Front) or Brake Caliper Bracket Replacement (Rear) in Rear Disc Brakes. Install the brake rotor. Refer to Brake Rotor Replacement (Front) or Brake Rotor Replacement (Rear) in Rear Disc Brakes. Tighten the strut to knuckle bolts to 112 Nm (82 ft. lbs.). 8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 9224 9. Lower the vehicle. 10. Adjust the rear wheel alignment. Refer to Measuring Wheel Alignment in Wheel Alignment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component Information > Specifications Rear Knuckle Alignment Link: Specifications Rear Spindle Rods to Knuckle Nut 110 ft.lb Rear Wheel Spindle Rods to Rear Suspension Support Nut 103 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component Information > Specifications > Page 9228 Rear Knuckle Alignment Link: Service and Repair Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. Important: Use a transmission jack or suitable hoist stands to prop the rear suspension support. 3. Lower the rear suspension support to gain clearance to the rear wheel spindle rod to rear suspension support bolt. 4. Remove the nut (1) from the rear wheel spindle rod at the rear suspension support. 5. Remove the rear wheel spindle rod to knuckle bolt and nut (2). 6. Push the rear wheel spindle rod to knuckle bolt forward enough to provide rear wheel spindle rod removal clearance. 7. Remove the rear wheel spindle rod. Installation Procedure 1. Install the rear wheel spindle rod. 2. Install the rear wheel spindle rod to the rear suspension support bolt. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component Information > Specifications > Page 9229 3. Install the rear wheel spindle rod to the rear suspension support nut (1). Tighten the rear wheel spindle rod to the rear suspension support nut to 140 Nm (103 ft. lbs.). 4. Connect the rear wheel spindle rod to the knuckle. 5. Install the rear wheel spindle rod to the knuckle bolt. 6. Install the rear wheel spindle rod to knuckle retaining nut (2). Tighten the rear wheel spindle rod to knuckle nut to 150 Nm (110 ft. lbs.). 7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 8. Lower the vehicle. 9. Adjust the wheel toe angle. Refer to Wheel Alignment Specifications (Front) or Wheel Alignment Specifications (Rear) in Wheel Alignment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Front Stabilizer Bushing: Service and Repair Front Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Move (turn) the tires in order to access the stabilizer shaft insulator brackets. 3. Remove the left and right side stabilizer shaft insulator bracket bolts. 4. Remove the left and right side stabilizer shaft insulator brackets. 5. Remove the left and right side stabilizer shaft insulators (1) from the stabilizer shaft (2). Installation Procedure 1. Install the left and right side stabilizer shaft insulators (1) to the stabilizer shaft (2). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Front > Page 9235 2. Install the left and right side stabilizer shaft insulator brackets. 3. Install the left and right side stabilizer shaft insulator bracket bolts. Notice: Refer to Fastener Notice in Service Precautions. Tighten the stabilizer shaft insulator bracket bolts to 48 Nm (35 inch lbs.). 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Front > Page 9236 Stabilizer Bushing: Service and Repair Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the bolt from the stabilizer shaft insulator bracket (3). 3. Remove the stabilizer shaft insulator bracket. 4. Remove the stabilizer shaft insulator (2) from the stabilizer shaft. Installation Procedure 1. Install the stabilizer shaft insulator (2) to the stabilizer shaft. 2. Install the stabilizer shaft insulator bracket (3). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the stabilizer shaft bracket nut. Tighten the nut to 48 Nm (35 ft. lbs.). 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications > Front Stabilizer Link: Specifications Front Stabilizer Shaft Link Nut 17 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications > Front > Page 9241 Stabilizer Link: Specifications Stabilizer Shaft Link Nuts 26 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Stabilizer Link: Service and Repair Front Removal Procedure 1. Raise the vehicle and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Remove the stabilizer shaft link bolt and nut. 4. Remove the stabilizer shaft link from the vehicle. Installation Procedure 1. Install the stabilizer link into the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the stabilizer shaft link bolt and nut. Tighten the stabilizer shaft link nut to 23 Nm (17 ft. lbs.). 3. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 9244 Stabilizer Link: Service and Repair Rear Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Remove the rear stabilizer shaft link (1) nut. 4. Disconnect the rear stabilizer shaft link from the strut. 5. Remove the stabilizer shaft link (1). Installation Procedure 1. Install the stabilizer shaft link (1). Tighten the stabilizer shaft link nut to 35 Nm (26 ft. lbs.). 2. Connect the stabilizer shaft link to the strut. Tighten the stabilizer shaft link to strut nut to 35 Nm (26 ft. lbs.). 3. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 9245 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Strut Tower Brace > Component Information > Service and Repair Strut Tower Brace: Service and Repair Cross Vehicle Brace Replacement Removal Procedure 1. Open the hood. 2. Remove the nuts from the cross vehicle brace. 3. Remove the cross vehicle brace from the vehicle. Important: Be careful, the stud plates may fall out and possibly get caught under the vehicle during the removal. 4. Remove the stud plates push on nuts from the studs. 5. Remove the stud plates from the vehicle. Installation Procedure Important: The stud plates will require an assistant to hold the stud plates during the installation of the push on nuts. 1. Install the stud plates to the vehicle. 2. Install the stud plates push on nuts to the studs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Strut Tower Brace > Component Information > Service and Repair > Page 9250 3. Install the cross vehicle brace to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the nuts to the cross vehicle brace. Tighten the cross vehicle brace nuts to 18 Nm (13 lb ft). 5. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair Front Subframe: Service and Repair Frame Removal Tools Required J 39580 Universal Engine Support Table Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the air cleaner assembly. 3. Install the engine support Fixture. 4. Raise and support the vehicle. 5. Remove the front tires and wheels. 6. Remove the steering gear mounting bolts. 7. Use a strap in order to secure the power steering gear. 8. Remove the engine mount to frame nuts. 9. Remove the transaxle mount to frame nuts. 10. Remove the power steering cooler pipe from the frame. 11. Use utility wire to secure the power steering cooler. 12. Disconnect the front wheel speed sensor connectors (1). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Page 9255 13. Remove the front wheel speed harness retainers from the frame and the lower control arms (2). 14. Separate both of the lower ball joints from the steering knuckle. 15. Lower the vehicle until the frame contacts the J 39580. 16. Remove and DISCARD all frame-to-body bolts. 17. Raise the vehicle in order to separate the frame from the body. 18. If you are replacing the frame, remove the following components: ^ The spacers, the upper insulators, the lower insulators, and the retainers. ^ Both of the lower control arms. ^ The stabilizer shaft. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Page 9256 1. If previously removed, install the following components: Important: Ensure that the insulators are completely seated against the frame. ^ The spacers, the upper insulators, the lower insulators, and the retainers. ^ Both of the lower control arms. ^ The stabilizer shaft. 2. Position the engine support table with the frame under the vehicle. 3. Lower the vehicle to the frame. 4. Align the frame to the body by inserting two 19 X 203 mm (0.74 X 8.0 in) pins in the alignment holes on the right side of the frame. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 5. Install the NEW frame-to-body bolts. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Page 9257 Tighten Tighten the bolts to 180 Nm (133 lb ft). 6. Install the engine mount nuts. 7. Install the transaxle mount nuts. 8. Connect the lower ball joints to the steering knuckle. 9. Install the steering gear mounting bolts. 10. Install the power steering cooler pipe to the frame. 11. Connect the front wheel speed sensor connectors (1). 12. Install the front wheel speed harness retainers from the frame and the lower control arms (2). 13. Remove the universal support table. 14. Install the front tires and wheels. 15. Lower the vehicle. 16. Remove the engine support fixture. 17. Connect the negative battery cable. 18. Install the air cleaner assembly. 19. Inspect the front wheel alignment and adjust if needed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > Customer Interest for Front Subframe Mount: > 00-08-61-003 > Oct > 00 > Frame - Clunk/Pop Noise Front Subframe Mount: Customer Interest Frame - Clunk/Pop Noise File In Section: 08 - Body and Accessories Bulletin No.: 00-08-61-003 Date: October, 2000 TECHNICAL Subject: Clunk/Pop Noise From Front Of Vehicle (Shim Rear Frame/Cradle Mounts) Models: 2000 Chevrolet Impala, Monte Carlo Condition Some customers may comment about a clunk or pop type noise coming from the front of the vehicle. This condition can be duplicated and is most apparent during either a heavy acceleration from a stop or moderate to heavy brake apply at low speeds. Cause This condition may be caused by fore/aft movement of the two rear frame/cradle mounts in the frame/cradle assembly. Correction Install shim material contained in service kit, P/N 10306243, between the rear mounts and the frame/cradle assembly, using the following procedure: 1. Raise vehicle and support the rear of the frame/cradle assembly. 2. Remove the two rear frame/cradle mount bolts and the lower retainers. 3. Lower the rear of the frame/cradle assembly 50 mm (2 in). 4. Remove the two rear mount upper insulators. 5. Remove the two rear mount lower insulators. 6. Cut shim material contained in service kit, P/N 10306243, into four equal pieces 25 mm X 62 mm (1 in X 2-1/2 in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > Customer Interest for Front Subframe Mount: > 00-08-61-003 > Oct > 00 > Frame - Clunk/Pop Noise > Page 9266 7. With the shiny surface of the shim material facing away from the mount lower insulators, position a piece of the shim material (1) on both the fore and aft surfaces of the insulators as shown in the figure. 8. While holding the shim material (1) in position, install lower insulators into the frame/cradle assembly. 9. Generously lubricate the upper insulators with rubber lubricate, P/N 12345884 and install. 10. Raise the rear of the frame/cradle assembly up to the vehicle underbody. 11. Install mount lower insulator retainers and hand start frame/cradle mount bolts. Tighten Tighten the frame/cradle mount bolts to 160 Nm (118 lb ft). 12. Remove the support and lower the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > Customer Interest for Front Subframe Mount: > 00-08-61-003 > Oct > 00 > Frame - Clunk/Pop Noise > Page 9267 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > 00-08-61-003 > Oct > 00 > Frame - Clunk/Pop Noise Front Subframe Mount: All Technical Service Bulletins Frame - Clunk/Pop Noise File In Section: 08 - Body and Accessories Bulletin No.: 00-08-61-003 Date: October, 2000 TECHNICAL Subject: Clunk/Pop Noise From Front Of Vehicle (Shim Rear Frame/Cradle Mounts) Models: 2000 Chevrolet Impala, Monte Carlo Condition Some customers may comment about a clunk or pop type noise coming from the front of the vehicle. This condition can be duplicated and is most apparent during either a heavy acceleration from a stop or moderate to heavy brake apply at low speeds. Cause This condition may be caused by fore/aft movement of the two rear frame/cradle mounts in the frame/cradle assembly. Correction Install shim material contained in service kit, P/N 10306243, between the rear mounts and the frame/cradle assembly, using the following procedure: 1. Raise vehicle and support the rear of the frame/cradle assembly. 2. Remove the two rear frame/cradle mount bolts and the lower retainers. 3. Lower the rear of the frame/cradle assembly 50 mm (2 in). 4. Remove the two rear mount upper insulators. 5. Remove the two rear mount lower insulators. 6. Cut shim material contained in service kit, P/N 10306243, into four equal pieces 25 mm X 62 mm (1 in X 2-1/2 in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > 00-08-61-003 > Oct > 00 > Frame - Clunk/Pop Noise > Page 9273 7. With the shiny surface of the shim material facing away from the mount lower insulators, position a piece of the shim material (1) on both the fore and aft surfaces of the insulators as shown in the figure. 8. While holding the shim material (1) in position, install lower insulators into the frame/cradle assembly. 9. Generously lubricate the upper insulators with rubber lubricate, P/N 12345884 and install. 10. Raise the rear of the frame/cradle assembly up to the vehicle underbody. 11. Install mount lower insulator retainers and hand start frame/cradle mount bolts. Tighten Tighten the frame/cradle mount bolts to 160 Nm (118 lb ft). 12. Remove the support and lower the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > 00-08-61-003 > Oct > 00 > Frame - Clunk/Pop Noise > Page 9274 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 9275 Front Subframe Mount: By Symptom Technical Service Bulletin # 00-08-61-003 Date: 001001 Frame - Clunk/Pop Noise File In Section: 08 - Body and Accessories Bulletin No.: 00-08-61-003 Date: October, 2000 TECHNICAL Subject: Clunk/Pop Noise From Front Of Vehicle (Shim Rear Frame/Cradle Mounts) Models: 2000 Chevrolet Impala, Monte Carlo Condition Some customers may comment about a clunk or pop type noise coming from the front of the vehicle. This condition can be duplicated and is most apparent during either a heavy acceleration from a stop or moderate to heavy brake apply at low speeds. Cause This condition may be caused by fore/aft movement of the two rear frame/cradle mounts in the frame/cradle assembly. Correction Install shim material contained in service kit, P/N 10306243, between the rear mounts and the frame/cradle assembly, using the following procedure: 1. Raise vehicle and support the rear of the frame/cradle assembly. 2. Remove the two rear frame/cradle mount bolts and the lower retainers. 3. Lower the rear of the frame/cradle assembly 50 mm (2 in). 4. Remove the two rear mount upper insulators. 5. Remove the two rear mount lower insulators. 6. Cut shim material contained in service kit, P/N 10306243, into four equal pieces 25 mm X 62 mm (1 in X 2-1/2 in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 9276 7. With the shiny surface of the shim material facing away from the mount lower insulators, position a piece of the shim material (1) on both the fore and aft surfaces of the insulators as shown in the figure. 8. While holding the shim material (1) in position, install lower insulators into the frame/cradle assembly. 9. Generously lubricate the upper insulators with rubber lubricate, P/N 12345884 and install. 10. Raise the rear of the frame/cradle assembly up to the vehicle underbody. 11. Install mount lower insulator retainers and hand start frame/cradle mount bolts. Tighten Tighten the frame/cradle mount bolts to 160 Nm (118 lb ft). 12. Remove the support and lower the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 9277 Disclaimer Technical Service Bulletin # 00-08-61-003 Date: 001001 Frame - Clunk/Pop Noise File In Section: 08 - Body and Accessories Bulletin No.: 00-08-61-003 Date: October, 2000 TECHNICAL Subject: Clunk/Pop Noise From Front Of Vehicle (Shim Rear Frame/Cradle Mounts) Models: 2000 Chevrolet Impala, Monte Carlo Condition Some customers may comment about a clunk or pop type noise coming from the front of the vehicle. This condition can be duplicated and is most apparent during either a heavy acceleration from a stop or moderate to heavy brake apply at low speeds. Cause This condition may be caused by fore/aft movement of the two rear frame/cradle mounts in the frame/cradle assembly. Correction Install shim material contained in service kit, P/N 10306243, between the rear mounts and the frame/cradle assembly, using the following procedure: 1. Raise vehicle and support the rear of the frame/cradle assembly. 2. Remove the two rear frame/cradle mount bolts and the lower retainers. 3. Lower the rear of the frame/cradle assembly 50 mm (2 in). 4. Remove the two rear mount upper insulators. 5. Remove the two rear mount lower insulators. 6. Cut shim material contained in service kit, P/N 10306243, into four equal pieces 25 mm X 62 mm (1 in X 2-1/2 in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 9278 7. With the shiny surface of the shim material facing away from the mount lower insulators, position a piece of the shim material (1) on both the fore and aft surfaces of the insulators as shown in the figure. 8. While holding the shim material (1) in position, install lower insulators into the frame/cradle assembly. 9. Generously lubricate the upper insulators with rubber lubricate, P/N 12345884 and install. 10. Raise the rear of the frame/cradle assembly up to the vehicle underbody. 11. Install mount lower insulator retainers and hand start frame/cradle mount bolts. Tighten Tighten the frame/cradle mount bolts to 160 Nm (118 lb ft). 12. Remove the support and lower the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 9279 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Service and Repair > Drivetrain and Front Suspension Frame Front Insulator Replacement Front Subframe Mount: Service and Repair Drivetrain and Front Suspension Frame Front Insulator Replacement Drivetrain and Front Suspension Frame Front Insulator Replacement Tools Required J 45296 Frame Insulator Remover/Installer Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Disconnect the steering intermediate shaft. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column. 3. Disconnect the fog lamp electrical connectors from the fog lamps. 4. Install a jackstand under the center of the frame, between the front frame insulators. 5. Remove the front frame bolts and retainers. 6. Lower the front of the frame. 7. Remove the frame front upper insulators. 8. Install the J 45296 to the front frame insulator you are removing. 9. Using J 45296 , remove the front frame insulator from the frame. Installation Procedure 1. Clean the front frame insulator opening. 2. Apply a thin coat of rubber lubricant GM P/N 1051717 or equivalent to the inside of the front frame insulator opening. 3. Apply a thin coat of rubber lubricant GM P/N 1051717 or equivalent to the front frame insulator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Service and Repair > Drivetrain and Front Suspension Frame Front Insulator Replacement > Page 9282 4. Align the front frame insulator to the front frame opening with the front frame alignment tabs facing to the front. 5. Using J 45296 , install the front frame insulator to the front frame. 6. Install the frame front upper insulators. 7. Raise the front of the frame. Notice: Refer to Fastener Notice in Cautions and Notices. 8. Install the front frame bolts and retainers. Tighten the front frame bolts to 180 Nm (133 lb ft). 9. Remove the jackstand. 10. Connect the fog lamp electrical connectors to the fog lamps. 11. Connect the steering intermediate shaft. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column. 12. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Service and Repair > Drivetrain and Front Suspension Frame Front Insulator Replacement > Page 9283 Front Subframe Mount: Service and Repair Drivetrain and Front Suspension Frame Rear Insulator Replacement Drivetrain and Front Suspension Frame Rear Insulator Replacement Removal Procedure Important: In order to remove any frame insulator, loosen the adjacent frame insulators to permit the frame to separate from the body. Do not break the fan shroud or damage the frame attachments, such as steering hoses and brake pipes during the replacement of body mounts. When installing a body mount, ensure the lower insulator is seated into the frame. The lower insulator should not be loose. The spacer and the corresponding upper insulator is pressed into the lower insulator thus squeezing the frame. The bolt is then inserted through the mount, capturing the lower retainer. The body mount components prevent contact of the frame to the body. Do not over tighten the body mount. Over tightening may collapse a spacer or strip a bolt. When the frame insulator bolts are removed, always discard the bolts and replace with new bolts. When clamping by the mount, ensure the surfaces are clean and dry. If the frame insulator bolt does not screw in smoothly, run a tap through the frame crossmember nut in the body in order to remove foreign material. Ensure the tap does not punch through the underbody. Whenever the body is moved in relation to the frame, disconnect the intermediate shaft from the rack and pinion steering gear and stub shaft. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the intermediate shaft from the steering gear stub shaft. Refer to Intermediate Steering Shaft Replacement in Power Steering System. 3. Install a utility stand to the rear of the frame. 4. Remove the rear frame bolts. 5. Lower the rear of the frame. 6. Remove the upper and lower insulators from the rear of the frame as a set. Installation Procedure 1. Apply lube to inside surface of lower insulator and to top surface of upper insulator. 2. Install the upper and lower insulators to the rear of the frame as a set. 3. Raise the rear of the frame. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Service and Repair > Drivetrain and Front Suspension Frame Front Insulator Replacement > Page 9284 Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the rear frame bolts. Tighten the rear frame bolts to 180 Nm (133 lb ft). 5. Remove the utility stand. 6. Install the intermediate shaft to the steering gear stub shaft. Refer to Intermediate Steering Shaft Replacement in Power Steering System. 7. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-03-08-002 > Feb > 02 > Suspension - Front of Vehicle Too Low or Bottoms Out Suspension Spring ( Coil / Leaf ): Customer Interest Suspension - Front of Vehicle Too Low or Bottoms Out File in Section: 03 - Suspension Bulletin No.: 02-03-08-002 Date: February, 2002 TECHNICAL Subject: Front of Vehicle Sits Too Low, Bottoms Out Over Bumps (Replace Front Coil Springs, Inspect/Replace Frame and Mount) Models: 2000-2001 Chevrolet Impala with RPO 9C1 Police Car and 9C3 SEO Vehicle Police Car, Limited Content Built Prior to VIN Breakpoint 29140498 Condition Some customers may comment that the front of the vehicle sits too low and bottoms out over bumps. Cause This condition may be caused by the additional weight of the Police Package added to the vehicle. Correction Follow the service procedure below. Measuring J and K Trim Heights 1. Place the vehicle on a level surface such as an alignment rack. 2. Set the tire pressures on all Police vehicles. Tire Inflation Pressure Specifications Set the tire inflation pressure for Police Vehicles at 240 kPa (35 psi). 3. Verify the fuel level. Add additional weight if necessary to simulate a full tank. 4. Remove any additional items from the vehicle's interior. 5. Empty the rear compartment except for the spare tire. 6. Close the deck lid. 7. Close the doors 8. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-03-08-002 > Feb > 02 > Suspension - Front of Vehicle Too Low or Bottoms Out > Page 9293 Important: ^ Lift the front bumper at the center 38 mm (1.05 in) and gently release allowing the vehicle to settle. Push the bumper down 38 mm (1.05 in) and gently release allowing the vehicle to rise. Repeat this procedure for the rear bumper. ^ All dimensions are measured vertical to the ground. 9. Measure the J and K heights 230 mm-250 mm (9.06 in-9.84 in). If the J and K heights are below the specifications listed above, replace the front strut coil springs, P/N 22133025. Refer to Strut, Strut Component and/or Spring Replacement in the Service Manual (SI2000 Document ID # 652878). Frame Inspection/Replacement 1. Raise the vehicle. Important: ^ Vehicles with damage to the front frame rail due to impacts with an object are not covered under warranty. ^ Scrapes on the front frame rail will be covered under warranty. 2. Inspect the frame along the front edge for damage due to the vehicle bottoming out. 3. Inspect the frame for bending using a straight edge along the right side of the frame rail below the engine mount. 4. Remove the frame if the frame is damaged or bent. Refer to Frame Replacement in Body and Accessories in the Service Manual (SI2000 Document ID # 728902). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-03-08-002 > Feb > 02 > Suspension - Front of Vehicle Too Low or Bottoms Out > Page 9294 5. Remove the bolts retaining the engine mount bracket to the engine. 6. Remove the engine mount from the bracket. 7. Replace the engine mount bracket with P/N 10321856. 8. Install the engine mount to the bracket. Tighten Tighten the engine mount upper nuts to 78 N.m (58 lb ft). 9. Install the engine mount bracket with the engine mount to the engine. Tighten Tighten the engine mount bracket bolts to 102 Nm (75 lb ft). Important: ^ Replace the frame mounting bolts, P/N 10403403. ^ Only replace the frame insulators if necessary, front upper P/N 10402880, front lower P/N 10402882, rear upper P/N 10402881, and rear lower P/N 10299475. 10. Replace the frame, P/N 10322679. Refer to Frame Replacement in Body and Accessories in the Service Manual (SI2000 Document ID # 793554). 11. Align the vehicle. Refer to Wheel Alignment in the Service Manual (SI2000 Document ID # 729569). Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-03-08-002 > Feb > 02 > Suspension - Front of Vehicle Too Low or Bottoms Out > Page 9295 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-03-08-002 > Feb > 02 > Suspension - Front of Vehicle Too Low or Bottoms Out Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Suspension - Front of Vehicle Too Low or Bottoms Out File in Section: 03 - Suspension Bulletin No.: 02-03-08-002 Date: February, 2002 TECHNICAL Subject: Front of Vehicle Sits Too Low, Bottoms Out Over Bumps (Replace Front Coil Springs, Inspect/Replace Frame and Mount) Models: 2000-2001 Chevrolet Impala with RPO 9C1 Police Car and 9C3 SEO Vehicle Police Car, Limited Content Built Prior to VIN Breakpoint 29140498 Condition Some customers may comment that the front of the vehicle sits too low and bottoms out over bumps. Cause This condition may be caused by the additional weight of the Police Package added to the vehicle. Correction Follow the service procedure below. Measuring J and K Trim Heights 1. Place the vehicle on a level surface such as an alignment rack. 2. Set the tire pressures on all Police vehicles. Tire Inflation Pressure Specifications Set the tire inflation pressure for Police Vehicles at 240 kPa (35 psi). 3. Verify the fuel level. Add additional weight if necessary to simulate a full tank. 4. Remove any additional items from the vehicle's interior. 5. Empty the rear compartment except for the spare tire. 6. Close the deck lid. 7. Close the doors 8. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-03-08-002 > Feb > 02 > Suspension - Front of Vehicle Too Low or Bottoms Out > Page 9301 Important: ^ Lift the front bumper at the center 38 mm (1.05 in) and gently release allowing the vehicle to settle. Push the bumper down 38 mm (1.05 in) and gently release allowing the vehicle to rise. Repeat this procedure for the rear bumper. ^ All dimensions are measured vertical to the ground. 9. Measure the J and K heights 230 mm-250 mm (9.06 in-9.84 in). If the J and K heights are below the specifications listed above, replace the front strut coil springs, P/N 22133025. Refer to Strut, Strut Component and/or Spring Replacement in the Service Manual (SI2000 Document ID # 652878). Frame Inspection/Replacement 1. Raise the vehicle. Important: ^ Vehicles with damage to the front frame rail due to impacts with an object are not covered under warranty. ^ Scrapes on the front frame rail will be covered under warranty. 2. Inspect the frame along the front edge for damage due to the vehicle bottoming out. 3. Inspect the frame for bending using a straight edge along the right side of the frame rail below the engine mount. 4. Remove the frame if the frame is damaged or bent. Refer to Frame Replacement in Body and Accessories in the Service Manual (SI2000 Document ID # 728902). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-03-08-002 > Feb > 02 > Suspension - Front of Vehicle Too Low or Bottoms Out > Page 9302 5. Remove the bolts retaining the engine mount bracket to the engine. 6. Remove the engine mount from the bracket. 7. Replace the engine mount bracket with P/N 10321856. 8. Install the engine mount to the bracket. Tighten Tighten the engine mount upper nuts to 78 N.m (58 lb ft). 9. Install the engine mount bracket with the engine mount to the engine. Tighten Tighten the engine mount bracket bolts to 102 Nm (75 lb ft). Important: ^ Replace the frame mounting bolts, P/N 10403403. ^ Only replace the frame insulators if necessary, front upper P/N 10402880, front lower P/N 10402882, rear upper P/N 10402881, and rear lower P/N 10299475. 10. Replace the frame, P/N 10322679. Refer to Frame Replacement in Body and Accessories in the Service Manual (SI2000 Document ID # 793554). 11. Align the vehicle. Refer to Wheel Alignment in the Service Manual (SI2000 Document ID # 729569). Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-03-08-002 > Feb > 02 > Suspension - Front of Vehicle Too Low or Bottoms Out > Page 9303 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Dust Shield, Suspension Strut > Component Information > Description and Operation Dust Shield: Description and Operation The dust shield is designed to protect the strut from dirt and corrosion. The shield also contains a strut jounce bumper. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Strut Mount > Component Information > Description and Operation Strut Mount: Description and Operation The upper steering pivot point (strut bearing) is located in the upper spring seat. The bearing is permanently lubricated. The bearing requires no service. The upper spring seat is plastic. The spring seat is offset at an angle in order to minimize side loads on the strut and on the upper strut mount bushing. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications Trailing Arm: Specifications Trailing Arm Bracket to Body Nut 40 ft.lb Trailing Arm to Knuckle Bolt 52 ft.lb + 65 degrees Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 9314 Trailing Arm: Service and Repair Removal Procedure Tools Required ^ J 36660-A Torque Angle Meter 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Disconnect the ABS electrical harness (1). 4. Disconnect the trailing arm (1) from the knuckle. 5. Disconnect the trailing arm (1) from the trailing arm bracket. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 9315 6. Remove the trailing arm (1). Installation Procedure 1. Connect the trailing arm (1) to the trailing arm bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bracket bolt/screw and nut. Tighten the bracket nut (1) to 105 Nm (77 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 9316 3. Connect the trailing arm to the knuckle. Tighten the trailing arm to knuckle nut (1) to 260 Nm (192 ft. lbs.). 4. Connect the ABS electrical harness (1). 5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 6. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use GC Wheel Bearing Grease. GC ....................................................................................................................................................... ............. Wheel Bearing Grease, NLGI Classification Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement Wheel Bearing: Service and Repair Front Wheel Drive Shaft Bearing Replacement Front Wheel Drive Shaft Bearing Replacement Removal Procedure Tools Required ^ J 28733-B Spindle Remover 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Disconnect the wheel speed sensor electrical connector (2). 4. Remove the wheel speed sensor electrical connector from the bracket. 5. Remove the brake caliper bracket with the brake caliper. Refer to Brake Caliper Bracket Replacement (Front) or Brake Caliper Bracket Replacement (Rear) in Brakes and Traction Control. 6. Remove the brake rotor. Refer to Brake Rotor Replacement (Front) or Brake Rotor Replacement (Rear) in Brakes and Traction Control. 7. Remove the wheel drive shaft nut. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement > Page 9322 8. Use three wheel nuts in order to attach the J 28733-B to the wheel bearing/hub. 9. Use the J 28733-B in order to push the wheel drive shaft out of the wheel bearing/hub. 10. Remove and DISCARD the wheel bearing/hub bolts. Important: Ensure that the wheel drive shaft outer seal (boot) is not damaged. 11. Remove the wheel bearing/hub. Installation Procedure 1. Install the wheel bearing/hub. Caution: These fasteners MUST be replaced with new fasteners anytime they become loose or are removed. Failure to replace these fasteners after they become loose or are removed may cause loss of vehicle control and personal injury. Notice: Refer to Fastener Notice in Service Precautions Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement > Page 9323 2. Install NEW wheel bearing/hub bolts. Tighten the NEW wheel bearing/hub bolts to 130 Nm (96 ft. lbs.). 3. Install the wheel drive shaft nut. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts. 4. Install the brake rotor. Refer to Brake Rotor Replacement (Front) or Brake Rotor Replacement (Rear) in Brakes and Traction Control. 5. Install the brake caliper bracket with the brake caliper. Refer to Brake Caliper Bracket Replacement (Front) or Brake Caliper Bracket Replacement (Rear) in Brakes and Traction Control. Important: Ensure that the connector clip engages the bracket properly. 6. Install the wheel speed sensor electrical connector to the bracket. 7. Connect the wheel speed sensor electrical connector (2). 8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 9. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement > Page 9324 Wheel Bearing: Service and Repair Wheel Bearing/Hub Replacement-Rear Wheel Bearing/Hub Replacement - Rear Removal Procedure The wheel bearing in the rear wheel hub is integrated into one unit. The hub is non-serviceable. If the hub and/or bearing is damaged, replace the complete hub and bearing assembly. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tires and wheels. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Remove the rear caliper and bracket. Refer to Brake Caliper Bracket Replacement (Rear) in Disc Brakes. 4. Remove the brake rotor. Refer to Brake Rotor Replacement (Rear) in Disc Brakes. 5. Disconnect the ABS electrical connector from the wheel speed sensor (1). Refer to Wheel Speed Sensor Replacement (Rear) in Antilock Brakes. 6. Remove the rear wheel hub-to-knuckle bolts. 7. Remove the rear wheel hub and park brake assembly from the knuckle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement > Page 9325 8. Remove the parking brake lever bracket (8). 9. Remove the parking brake actuator (6). Installation Procedure 1. Install the parking brake lever bracket (8). 2. Install the parking brake actuator (6). 3. Install the rear wheel hub and park brake assembly to the knuckle. Notice: Refer to Fastener Notice in Service Precautions. 4. Install new rear wheel hub-to-knuckle bolts. Tighten the hub mounting bolts to 75 Nm (55 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement > Page 9326 5. Connect the ABS electrical connector to the wheel speed sensor (1). Refer to Wheel Speed Sensor Replacement (Rear) in Antilock Brakes. 6. Install the brake rotor. Refer to Brake Rotor Replacement (Rear) in Disc Brakes. 7. Install the rear caliper and bracket. Refer to Brake Caliper Bracket Replacement (Rear) in Disc Brakes. 8. Install the tires and wheels. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 9. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Wheel Drive Shaft Nut 159 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Locations Low Tire Pressure Indicator: Locations Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Locations > Page 9346 Component Locator Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions Low Tire Pressure Indicator: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9349 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9350 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9351 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9352 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9353 Low Tire Pressure Indicator: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9354 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9355 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9356 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9357 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9358 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9359 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9360 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9361 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9362 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9363 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9364 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9365 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9366 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9367 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9368 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9369 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9370 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9371 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9372 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9373 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9374 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9375 Low Tire Pressure Indicator: Electrical Diagrams Schematic and Routing Diagrams Tire Pressure Monitoring System Schematics (EBCM, Power, Ground and Instrument Cluster) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9376 Tire Pressure Monitoring System Schematics (Wheel Speed Sensors) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9377 Tire Pressure Monitoring System Schematics: EBCM, Power, Ground And Instrument Cluster Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9378 Tire Pressure Monitoring System Schematics: Wheel Speed Sensors Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Low Tire Pressure Warning System (LTPWS) Low Tire Pressure Indicator: Description and Operation Low Tire Pressure Warning System (LTPWS) Tire Inflation Monitoring System Operation The tire pressure monitor (TPM) system alerts the driver when the pressure changes in one of the tires. The system only detects a low pressure condition while the vehicle is being driven. Once a low tire pressure condition is detected, the system informs the driver whenever the ignition is ON. The LOW TIRE PRESSURE indicator illuminates if the tire pressure in one or more tires become at least 52 kPa (12 psi) lower or higher than the other tires. The message does not appear if the system is not calibrated properly. The system does not inform the driver which tire is low. To clear this message., set the tire pressures in all four tires to the proper pressures and perform the system reset procedure. Refer to Tire Inflation Monitor Reset Procedure for service procedure. See: Testing and Inspection The Tire Pressure Monitor software requires approximately One half hour of straight line driving to complete the TPM autolearn. There 'are several speed ranges' that the EBCM needs to learn the tire inflation configuration in order to have the full capability of detecting a low tire condition. The speed detection ranges are the following: ^ 24~64 km/h (15-40 mph) ^ 64-113km/h (40-70 mph) ^ 113-145 km/h (7O~90 mph) Each speed range has 2 modes of low tire detection. ^ Monitor Mode 1 ^ Monitor Mode 2 The, EBCM learns the tire inflation configuration for each speed range independently. In Monitor Mode 1, the EBCM has only partially learned the tire inflation configuration for the speed range and has limited detection capability for a low tire condition. In Monitor Mode 2, the EBCM has fully learned the tire inflation configuration for the speed range and has full detection capability for a low tire condition. If the EBCM is not in Monitor Mode 1 or Monitor Mode 2, a low tire condition cannot be detected because the EBCM has not learned the tire inflation configuration of the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Low Tire Pressure Warning System (LTPWS) > Page 9381 Low Tire Pressure Indicator: Description and Operation Tire Inflation Monitoring System Operation The tire pressure monitor (TPM) system alerts the driver when the pressure changes in one of the tires. The system only detects a low pressure condition while the vehicle is being driven. Once a low tire pressure condition is detected, the system informs the driver whenever the ignition is ON. The LOW TIRE PRESSURE indicator illuminates if the tire pressure in one or more tires become at least 82 kPa (12 psi) lower or higher than the other tires. The message does not appear if the system is not calibrated properly. The system does not inform the driver which tire is low. To clear this message, set the tire pressures in all four tires to the proper pressures and perform the system reset procedure. Refer to Tire Inflation Monitor Reset Procedure for service procedure. The Tire Pressure Monitor software requires approximately one half hour of straight line driving to complete the TPM auto-learn. There are several speed ranges that the EBCM needs to learn the tire inflation configuration in order to have the full capability of detecting a low tire condition. The speed detection ranges are the following: ^ 24-64 km/h (15-40 mph) ^ 64-113 km/h (40-70 mph) ^ 113-145 km/h (70-90 mph) Each speed range has 2 modes of low tire detection. ^ Monitor Mode 1 ^ Monitor Mode 2 The EBCM learns the tire inflation configuration for each speed range independently. In Monitor Mode 1, the EBCM has only partially learned the tire inflation configuration for the speed range and has limited detection capability for a low tire condition. In Monitor Mode 2, the EBCM has fully learned the tire inflation configuration for the speed range and has full detection capability for a low tire condition. If the EBCM is not in Monitor Mode 1 or Monitor Mode 2, a low tire condition cannot be detected because the EBCM has not learned the tire inflation configuration of the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair Spare Tire: Service and Repair The compact spare uses a narrow 4-inch wide rim. The wheel diameter is usually one inch larger than the road wheels. Do not use standard tires or snow tires on a compact spare wheel or damage to the vehicle may result. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause serious personal injury. Periodically check the inflation pressure of the compact spare and maintain this pressure at 415 kPa (60 psi). Use the present tire changing equipment and procedures to mount and dismount the compact tire from its wheel. As with other tires, the beads should completely seat at 275 kPa (40 psi). You may then safely inflate the spare tire to 415 kPa (60 psi). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 9402 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 9403 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 9404 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 9409 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 9414 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 9415 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 9416 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 9422 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 9423 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 9424 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 9429 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 9434 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 9435 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 9440 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 9441 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 9442 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 9447 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 9452 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 9453 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 9454 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-07-30-022B > Oct > 03 > A/T - MIL/SES Lamp ON/Multiple A/T DTC's Set Wiring Harness: All Technical Service Bulletins A/T - MIL/SES Lamp ON/Multiple A/T DTC's Set Bulletin No.: 02-07-30-022B Date: October 20, 2003 TECHNICAL Subject: Service Engine Soon (SES) Light On With DTCs P0716 and/or P0717, P0730, P0753, P0758, P1860, P1887, or other Miscellaneous Transmission Trouble Codes Set (Repair Wiring at Transaxle Wiring Pass-thru Connector) Models: 2000-2004 Buick Century, LeSabre, Park Avenue, Regal 2003-2004 Buick Rendezvous 2000-2001 Chevrolet Lumina 2000-2004 Chevrolet Cavalier, Impala, Malibu, Monte Carlo, Venture 2004 Chevrolet Classic 2000-2002 Oldsmobile Intrigue 2000-2003 Oldsmobile Aurora 2000-2004 Oldsmobile Alero, Silhouette 2000-2004 Pontiac Bonneville, Grand Am, Grand Prix, Montana, Sunfire 2001-2004 Pontiac Aztek 2000 Toyota Cavalier with 4T65-E, 4T40-E or 4T45-E Transaxle (RPOs MN3, MN7, M15, M76, MN4, MN5) Supercede: This bulletin is being revised to add the 2004 model year as well as the Chevrolet Classic model. Please discard Corporate Bulletin Number 02-07-30-022A (Section 07-Transmission/Transaxle). Condition Some customers may comment that the Service Engine Soon (SES) indicator is illuminated and that while the light is illuminated, transmission shifts are extremely harsh. Cause These types of conditions may be caused by an intermittent connection at the transaxle 20-way connector to the wiring harness interface. Correction If a DTC was recorded and the Freeze Frame and Failure Records back it up, a problem existed at one time with the wiring and/or the connectors between the transaxle and the PCM. Therefore, a thorough inspection and/or repair of the wiring harness at the transaxle 20-way connector for one or more of the following conditions may be warranted. ^ The wiring harness is stretched too tightly or other components are pressing on the connector body itself causing a downward pressure on the connector body and possible intermittent contact of the wiring terminals. Ensure proper clearance to any other components and wiring (i.e. hoses, battery cables, etc.). ^ The terminals are not fully seated into the cavity of the connector body. ^ The male terminals in the transaxle portion of the connector may be in the wrong position (i.e. bent). ^ The female terminals may be loose and are not making proper contact. Check the tension with the proper terminal tester from the GM Terminal Test Kit J 35616-A or J 35616-92. If the tension is low, replace the terminal. Do not try to re-form the terminal. ^ The crimp of the terminal to the wire may not be satisfactory (i.e. loose, over insulation, etc.). ^ The wiring connector is not properly seated and locked in position. Ensure proper seating of the connector into the transaxle and that the connector is properly locked in place. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-07-30-022B > Oct > 03 > A/T - MIL/SES Lamp ON/Multiple A/T DTC's Set > Page 9464 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-07-30-022B > Oct > 03 > A/T - MIL/SES Lamp ON/Multiple A/T DTC's Set > Page 9470 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 9471 Wheels: Service Precautions Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. Remove and install the tire over the curb-side bead seat. Machines which do not have a flat bed for the wheel to rest may cause cosmetic damage when the wheel is being clamped down. The bottom bead breaker on some machines may also cause cosmetic damage. Most tire changing equipment manufacturers have aluminum wheel adapter kits and plastic or Teflon(R) coated tools which will prevent cosmetic damage. Even with these kits you must modify some machines. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 9472 Wheels: Testing and Inspection Notice: The use of non-GM original equipment wheels may cause: ^ Damage to the wheel bearing, the wheel fasteners and the wheel ^ Tire damage caused by the modified clearance to the adjacent vehicle components ^ Adverse vehicle steering stability caused by the modified scrub radius ^ Damage to the vehicle caused by the modified ground clearance ^ Speedometer and odometer inaccuracy Important: Replacement wheels must be equivalent to the original equipment wheels in load capacity, diameter, rim width, offset and mounting configuration. A wheel of improper size or type may affect the wheel and bearing life, the brake cooling, the speedometer/odometer calibration, the vehicle ground clearance and the tire clearance to the body and the chassis. Replace wheels under the following conditions: ^ The wheels are bent or dented ^ The wheels have excessive radial runout ^ The wheels leak air through the wheel welds ^ The wheels have elongated bolt holes ^ The wheel nuts do not stay tight ^ The wheels are very rusty Wheels with excessive runout may cause objectionable vibrations. Steel wheels are identified by a two or three letter code stamped into the rim near the valve stem. Aluminum wheels have the code, part number, and manufacturer ID cast into their back side. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Repair Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation. 3. Use the following procedure to locate the leaking areas: ^ Inflate the tire to 275 kPa (40 psi). ^ Dip the tire and wheel into a water bath. 4. Mark the leak areas. 5. Remove the tire from the wheel. 6. Use 80 grit sandpaper to scuff the inside surface at the leak area. 7. Use a general purpose cleaner such as 3M #08984 or equivalent to clean the area. 8. Apply a 1/8-inch thick layer of adhesive sealant GM P/N 1052366 or equivalent to the leak area. 9. Allow 12 hours of drying time. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause serious personal injury. 1. Install the tire on the wheel. 2. Pressurize to 275 kPa (40 psi). 3. Inspect for leaks. 4. Adjust the tire pressure in order to meet the specifications. Refer to Tire Inflation Pressure Specifications. 5. Balance the tire and wheel assembly. Refer to Vibration Diagnosis and Correction under Steering and Suspension Testing and Inspection. 6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation. 7. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 9475 Wheels: Service and Repair Aluminum Wheel Refinishing A protective clear coat and/or base color coats the surface of the original equipment cast aluminum wheels. Surface degradation may develop from the use of wrong balance weights. Frequent, repeated automatic car wash cleaning from facilities using aggressive silicon carbide tipped tire brushes for cleaning whitewalls and tires may also damage the finish. Once the protective clear coat is damaged, exposure to caustic cleaners and/or road salt causes further surface degradation. The refinishing of aluminum wheels requires that the wheel surface be plastic media blasted in order to remove old clear coat or paint. The re-machining or the use of chemical strippers is not recommended due to concerns of repair durability. The service procedure details how to strip, clean and recoat aluminum wheel rims that are affected by the above condition. Required Materials You may use three different paint systems to refinish aluminum wheels. These products have shown the required repair durability. These products are the only paint systems that meet General Motors specification 4350M-A336. ^ System 1: Dupont Products ^ System 2: PPG Products ^ System 3: Spies Hecker Color Selection If the wheels being painted were previously clear coated aluminum, the use of Corsican SILVER WAEQ9283 for a fine aluminum-like look or Sparkle SILVER WA9967 for a very bright look is recommended. Refer to the paint manufacturer's color book for body color selection and verification. Refinish all four wheels and their center caps to ensure color uniformity. Important: Refer to and follow the individual formula and process which the manufacturer of each specific paint system provides. Use the products listed as a system only. Do not mix other manufacturers' product lines with the required materials of a given system. The products listed in this manual have shown the required repair durability. These products are the only paint systems that meet General Motors specification 435M-A336. Repair Procedure Caution: To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 1. Remove the wheels from the vehicle. Refer to Tire and Wheel Removal and Installation. Keep the tires mounted on the wheels. 2. Mark the location of the weights on the tire. 3. Remove the balance weights. 4. Record the value of each weight for reinstallation. 5. Use wax and grease remover to wipe any excess grease and/or dirt from the wheels. Important: The re-machining of aluminum wheels or the use of chemical strippers is not recommended due to concerns of durability. 6. Blast the wheels with plastic media in order to remove old paint or clear coat. 7. Mask off the wheels and tires. 8. Refer to and follow the individual painting formula and process provided by the manufacturer of each specific paint system. 9. Unmask the wheels and tires. 10. Install the new coated balance weights at the locations marked on the tires. 11. Clean all wheel mounting surfaces of any corrosion, overspray or dirt. Install the wheels to the vehicle. Refer to Tire and Wheel Removal and Installation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 9476 Wheels: Service and Repair Steel Wheel Repair Wheel repairs that use welding, heating, or peening are not approved. An inner tube is not an acceptable repair for leaky wheels or tires. If a steel wheel is found to be leaking, replace the wheel with one of original equipment quality. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use GC Wheel Bearing Grease. GC ....................................................................................................................................................... ............. Wheel Bearing Grease, NLGI Classification Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement Wheel Bearing: Service and Repair Front Wheel Drive Shaft Bearing Replacement Front Wheel Drive Shaft Bearing Replacement Removal Procedure Tools Required ^ J 28733-B Spindle Remover 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Disconnect the wheel speed sensor electrical connector (2). 4. Remove the wheel speed sensor electrical connector from the bracket. 5. Remove the brake caliper bracket with the brake caliper. Refer to Brake Caliper Bracket Replacement (Front) or Brake Caliper Bracket Replacement (Rear) in Brakes and Traction Control. 6. Remove the brake rotor. Refer to Brake Rotor Replacement (Front) or Brake Rotor Replacement (Rear) in Brakes and Traction Control. 7. Remove the wheel drive shaft nut. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement > Page 9482 8. Use three wheel nuts in order to attach the J 28733-B to the wheel bearing/hub. 9. Use the J 28733-B in order to push the wheel drive shaft out of the wheel bearing/hub. 10. Remove and DISCARD the wheel bearing/hub bolts. Important: Ensure that the wheel drive shaft outer seal (boot) is not damaged. 11. Remove the wheel bearing/hub. Installation Procedure 1. Install the wheel bearing/hub. Caution: These fasteners MUST be replaced with new fasteners anytime they become loose or are removed. Failure to replace these fasteners after they become loose or are removed may cause loss of vehicle control and personal injury. Notice: Refer to Fastener Notice in Service Precautions Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement > Page 9483 2. Install NEW wheel bearing/hub bolts. Tighten the NEW wheel bearing/hub bolts to 130 Nm (96 ft. lbs.). 3. Install the wheel drive shaft nut. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts. 4. Install the brake rotor. Refer to Brake Rotor Replacement (Front) or Brake Rotor Replacement (Rear) in Brakes and Traction Control. 5. Install the brake caliper bracket with the brake caliper. Refer to Brake Caliper Bracket Replacement (Front) or Brake Caliper Bracket Replacement (Rear) in Brakes and Traction Control. Important: Ensure that the connector clip engages the bracket properly. 6. Install the wheel speed sensor electrical connector to the bracket. 7. Connect the wheel speed sensor electrical connector (2). 8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 9. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement > Page 9484 Wheel Bearing: Service and Repair Wheel Bearing/Hub Replacement-Rear Wheel Bearing/Hub Replacement - Rear Removal Procedure The wheel bearing in the rear wheel hub is integrated into one unit. The hub is non-serviceable. If the hub and/or bearing is damaged, replace the complete hub and bearing assembly. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tires and wheels. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Remove the rear caliper and bracket. Refer to Brake Caliper Bracket Replacement (Rear) in Disc Brakes. 4. Remove the brake rotor. Refer to Brake Rotor Replacement (Rear) in Disc Brakes. 5. Disconnect the ABS electrical connector from the wheel speed sensor (1). Refer to Wheel Speed Sensor Replacement (Rear) in Antilock Brakes. 6. Remove the rear wheel hub-to-knuckle bolts. 7. Remove the rear wheel hub and park brake assembly from the knuckle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement > Page 9485 8. Remove the parking brake lever bracket (8). 9. Remove the parking brake actuator (6). Installation Procedure 1. Install the parking brake lever bracket (8). 2. Install the parking brake actuator (6). 3. Install the rear wheel hub and park brake assembly to the knuckle. Notice: Refer to Fastener Notice in Service Precautions. 4. Install new rear wheel hub-to-knuckle bolts. Tighten the hub mounting bolts to 75 Nm (55 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Drive Shaft Bearing Replacement > Page 9486 5. Connect the ABS electrical connector to the wheel speed sensor (1). Refer to Wheel Speed Sensor Replacement (Rear) in Antilock Brakes. 6. Install the brake rotor. Refer to Brake Rotor Replacement (Rear) in Disc Brakes. 7. Install the rear caliper and bracket. Refer to Brake Caliper Bracket Replacement (Rear) in Disc Brakes. 8. Install the tires and wheels. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 9. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Service and Repair Wheel Cover: Service and Repair Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation. 3. Place a squared off block of wood approximately 50 mm (2 inch) diameter against the back surface of the cap. 4. Use a hammer to strike the block of wood to remove the cap. Installation Procedure Notice: Failure to hit the cap squarely without the load distributed evenly could result in permanent damage to the cap. 1. Place the cap into position at the wheel opening. 2. Place a block of wood at least 76 mm (3 inch) diameter against the cap face. 3. Use a hammer to strike the block of wood to install the cap. 4. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation. 5. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Wheel Drive Shaft Nut 159 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 9502 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels Plastic Wheel Nut Covers Loose/Missing > Page 9508 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99-03-10-103 > Oct > 99 > Wheels Stud Removal Tool Change Wheel Fastener: All Technical Service Bulletins Wheels - Stud Removal Tool Change File In Section: 03 - Suspension Bulletin No.: 99-03-10-103 Date: October, 1999 INFORMATION Subject: Discontinue Usage of Tool J 6627-A for Wheel Stud Removal Models: 1992-99 Buick Riviera 1992-2000 Buick Century, LeSabre, Park Avenue, Regal 1992-2000 Cadillac DeVille, Eldorado, Seville 1992-96 Chevrolet Lumina APV 1997 Chevrolet Corvette (C-5) 1997-2000 Chevrolet Venture 2000 Chevrolet Impala, Monte Carlo 1992-99 Oldsmobile Aurora, Eighty Eight, Regency 1992-2000 Oldsmobile Silhouette 1998-2000 Oldsmobile Intrigue 1992-98 Pontiac Trans Sport 1992-2000 Pontiac Bonneville, Grand Prix 1999-2000 Pontiac Montana SPECIAL TOOL J 6627-A IS NOT TO BE USED AS THE WHEEL STUD REMOVAL TOOL FOR THE ABOVE VEHICLES. Notice: The fingers of J 6627-A extend too far down the back of the wheel hub and bearing assembly. When this tool is used as a wheel stud press, it may cause damage to the wheel hub inner seal. If the seal is damaged, water intrusion may occur and the life span of the wheel hub and bearing assembly may be decreased. Important: If any seal is damaged, it is recommended that the wheel hub and bearing assembly be replaced. USE OF EITHER SPECIAL TOOL J 35917 OR J 43631 IS RECOMMENDED IN ORDER TO PROPERLY REMOVE THE WHEEL STUDS ON THE VEHICLES LISTED ABOVE. These tools have similar dimensions and differ slightly in appearance, therefore, only one illustration is included. Notice: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99-03-10-103 > Oct > 99 > Wheels Stud Removal Tool Change > Page 9513 Do not remove the wheel studs with a hammer. This technique can potentially damage the wheel hub and bearing assembly. In addition to using special tool J 35917 or J 43631, the following vehicles require the front wheel hub bearing to be removed from the front aluminum knuckle in order to replace the wheel stud: - 1995-99 Buick Riviera - 1997-2000 Buick Century, Park Avenue Regal - 2000 Buick LeSabre - 1997-2000 Cadillac DeVille, Eldorado, Seville - 1997 Chevrolet Corvette (C-S) - 1997-2000 Chevrolet Venture - 2000 Chevrolet Impala, Monte Carlo - 1995-99 Oldsmobile Aurora - 1997-2000 Oldsmobile Silhouette - 1998-2000 Oldsmobile Intrigue - 1997-98 Pontiac Trans Sport - 1997-2000 Pontiac Grand Prix - 1999-2000 Pontiac Montana - 2000 Pontiac Bonneville Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 99-03-10-103 > Oct > 99 > Wheels - Stud Removal Tool Change Wheel Fastener: All Technical Service Bulletins Wheels - Stud Removal Tool Change File In Section: 03 - Suspension Bulletin No.: 99-03-10-103 Date: October, 1999 INFORMATION Subject: Discontinue Usage of Tool J 6627-A for Wheel Stud Removal Models: 1992-99 Buick Riviera 1992-2000 Buick Century, LeSabre, Park Avenue, Regal 1992-2000 Cadillac DeVille, Eldorado, Seville 1992-96 Chevrolet Lumina APV 1997 Chevrolet Corvette (C-5) 1997-2000 Chevrolet Venture 2000 Chevrolet Impala, Monte Carlo 1992-99 Oldsmobile Aurora, Eighty Eight, Regency 1992-2000 Oldsmobile Silhouette 1998-2000 Oldsmobile Intrigue 1992-98 Pontiac Trans Sport 1992-2000 Pontiac Bonneville, Grand Prix 1999-2000 Pontiac Montana SPECIAL TOOL J 6627-A IS NOT TO BE USED AS THE WHEEL STUD REMOVAL TOOL FOR THE ABOVE VEHICLES. Notice: The fingers of J 6627-A extend too far down the back of the wheel hub and bearing assembly. When this tool is used as a wheel stud press, it may cause damage to the wheel hub inner seal. If the seal is damaged, water intrusion may occur and the life span of the wheel hub and bearing assembly may be decreased. Important: If any seal is damaged, it is recommended that the wheel hub and bearing assembly be replaced. USE OF EITHER SPECIAL TOOL J 35917 OR J 43631 IS RECOMMENDED IN ORDER TO PROPERLY REMOVE THE WHEEL STUDS ON THE VEHICLES LISTED ABOVE. These tools have similar dimensions and differ slightly in appearance, therefore, only one illustration is included. Notice: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 99-03-10-103 > Oct > 99 > Wheels - Stud Removal Tool Change > Page 9519 Do not remove the wheel studs with a hammer. This technique can potentially damage the wheel hub and bearing assembly. In addition to using special tool J 35917 or J 43631, the following vehicles require the front wheel hub bearing to be removed from the front aluminum knuckle in order to replace the wheel stud: - 1995-99 Buick Riviera - 1997-2000 Buick Century, Park Avenue Regal - 2000 Buick LeSabre - 1997-2000 Cadillac DeVille, Eldorado, Seville - 1997 Chevrolet Corvette (C-S) - 1997-2000 Chevrolet Venture - 2000 Chevrolet Impala, Monte Carlo - 1995-99 Oldsmobile Aurora - 1997-2000 Oldsmobile Silhouette - 1998-2000 Oldsmobile Intrigue - 1997-98 Pontiac Trans Sport - 1997-2000 Pontiac Grand Prix - 1999-2000 Pontiac Montana - 2000 Pontiac Bonneville Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Torque Wheel Fastener: Specifications Wheel Fastener Torque Wheel Fastener Torque Wheel Fastener 100 ft.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Torque > Page 9522 Lug Nut Torque Patterns Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 9523 Wheel Fastener: Description and Operation Metric wheel nuts have the word Metric stamped on the face. The letter M is stamped at the end of the metric wheel stud. Thread size of the metric wheel nuts and studs is indicated by the following example: M12 x 1.5 ^ M = Metric ^ 12 = Diameter in millimeters ^ 1.5 = Millimeters per thread (gap between) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 9524 Wheel Fastener: Service and Repair Removal Procedure Tools Required ^ J 35917 Wheel Bolt Remover 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Remove the brake caliper and bracket. Refer to Brake Caliper Bracket Replacement (Front) or Brake Caliper Bracket Replacement (Rear) in Disc Brakes. 4. Remove the rotor (3). Refer to Brake Rotor Replacement (Front) or Brake Rotor Replacement (Rear) in Disc Brakes. 5. Use the J 35917 (2) to extract the wheel hub bolt from the hub (1). 6. Clean the wheel hub flange and clean the rotor of any corrosion, metal chips or foreign material. Installation Procedure 1. Install the replacement bolt in the wheel hub (1). 2. Add enough washers to draw the bolt into the hub. Important: Seat the wheel bolt fully against the hub flange. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the wheel nut with the flat side to the washers. Tighten the wheel nut until the wheel bolt head seats against the hub flange. 4. Back off the wheel nut. 5. Remove the washers. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 9525 6. Install the rotor (3). Refer to Brake Rotor Replacement (Front) or Brake Rotor Replacement (Rear) in Disc Brakes. 7. Install the brake caliper. Refer to Brake Caliper Bracket Replacement (Front) or Brake Caliper Bracket Replacement (Rear) in Disc Brakes. 8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 9. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 9526 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Mechanical Specifications Accumulator HVAC: Mechanical Specifications Accumulator Bracket Bolt 4 Nm Compressor Hose to Accumulator Nut 16 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Mechanical Specifications > Page 9532 Accumulator HVAC: Capacity Specifications If the refrigerant oil was removed from the A/C system during the recovery process or during the component replacement, the refrigerant oil must be replenished. Add the refrigerant oil as indicated. A/C Compressor 60 ml (2oz) Condensor 30 ml (1 oz) Evaporator 90 ml (3 oz) Accumulator 30 ml (1 oz plus amount removed) Abrupt oil loss due to a large refrigerant leak Add 90 ml (3 oz) plus the required amount for the component being replaced 9 cause of the large leak. Refrigerant Oil type is Polyalkylene Glycol (PAG) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 9533 Accumulator HVAC: Description and Operation Accumulator Description The sealed accumulator is connected to the evaporator outlet pipe. The accumulator stores the refrigerant (vapor and liquid) and the oil from the evaporator. A desiccant at the accumulator bottom dries any moisture in the system. An oil bleed hole at the accumulator outlet pipe end provides the oil return path to the compressor. The accumulator is not serviceable and should only be replaced when leaking due to the following conditions: ^ Perforation ^ A damaged sealing area ^ Damaged fastener threads ^ Outside air has entered the system for extended periods of time Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 9534 Accumulator HVAC: Service and Repair ACCUMULATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner and duct assembly. 2. Remove the cross vehicle brace. 3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 4. Remove the suction hose nut at the accumulator and position the suction hose aside. 5. Remove the compressor hose nut from the accumulator and position the compressor hose aside. 6. Remove the accumulator bracket bolt. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 9535 7. Remove the accumulator. INSTALLATION PROCEDURE 1. Install the accumulator. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the accumulator bracket bolt. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 9536 Tighten Tighten the accumulator bracket bolt to 4 N.m (36 lb in). IMPORTANT: Lubricate the new O-ring seals and seal washers with a mineral base 525 viscosity refrigerant oil. 3. Install the new O-ring seals onto the compressor hose and the suction hose. Refer to O-ring Replacement. 4. Install the compressor hose to the accumulator. Tighten Tighten the compressor hose nut to 16 N.m (12 lb ft). 5. Install the suction hose onto the accumulator Tighten Tighten the suction hose nut to 47 N.m (35 lb ft). 6. Evacuate and charge the system. Refer to Refrigerant Recovery and Recharging. See: Refrigerant/Service and Repair 7. Inspect the system for leaks. 8. Install the cross vehicle brace. 9. Install the air cleaner and duct assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 00-01-38-003A > Jan > 01 > Heating/AC - Popping Noise From Dash Area Air Door Actuator / Motor: Customer Interest Heating/AC - Popping Noise From Dash Area File In Section: 01 HVAC Bulletin No.: 00-01-38-003A Date: January, 2001 TECHNICAL Subject: Popping Sound Heard Underneath Instrument Panel When Switching from Defrost to Heat or from A/C to Defrost (Replace Mode Valve Actuator) Models: 2000 Chevrolet Impala, Monte Carlo This bulletin is being revised to update the text. Please discard Corporate Bulletin Number 00-01-38-003 (Section 01 - HVAC). Condition Some customers may comment that a popping sound is heard from underneath the instrument panel when switching from defrost to heat or from A/C to defrost. Cause The mode valve actuator may have a bind in the linkage. Correction 1. Remove the left (driver's) side instrument panel sound insulator panel. 2. Remove the left (driver's) side knee bolster. 3. Disconnect the two vacuum lines from the mode valve actuator. The mode valve actuator is behind the instrument panel just to the left of the radio and HVAC control. It has a blue vacuum line attached to the left side and a brown vacuum line on the back side. 4. Disconnect the mode valve actuator from it's attachment to the HVAC module case. Notice: The mode door arm is plastic. Care must be taken to avoid damaging the mode door arm. 5. Disconnect the mode door actuator from the mode door arm. 6. Install the new mode valve actuator, P/N 52487750 (this is replacing P/N 52487554), to the mode valve actuator arm and snap into place on the HVAC module case. 7. Connect the vacuum lines to the actuator. 8. Install the driver's knee bolster. 9. Tighten Tighten the screws to 2 Nm (18 lb in). 10. Install the left side instrument panel sound insulator panel. Parts Information Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 00-01-38-003A > Jan > 01 > Heating/AC - Popping Noise From Dash Area > Page 9546 Warranty Information For vehicles repaired under warranty, use the table. DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 00-01-38-003A > Jan > 01 > Heating/AC - Popping Noise From Dash Area Air Door Actuator / Motor: All Technical Service Bulletins Heating/AC - Popping Noise From Dash Area File In Section: 01 HVAC Bulletin No.: 00-01-38-003A Date: January, 2001 TECHNICAL Subject: Popping Sound Heard Underneath Instrument Panel When Switching from Defrost to Heat or from A/C to Defrost (Replace Mode Valve Actuator) Models: 2000 Chevrolet Impala, Monte Carlo This bulletin is being revised to update the text. Please discard Corporate Bulletin Number 00-01-38-003 (Section 01 - HVAC). Condition Some customers may comment that a popping sound is heard from underneath the instrument panel when switching from defrost to heat or from A/C to defrost. Cause The mode valve actuator may have a bind in the linkage. Correction 1. Remove the left (driver's) side instrument panel sound insulator panel. 2. Remove the left (driver's) side knee bolster. 3. Disconnect the two vacuum lines from the mode valve actuator. The mode valve actuator is behind the instrument panel just to the left of the radio and HVAC control. It has a blue vacuum line attached to the left side and a brown vacuum line on the back side. 4. Disconnect the mode valve actuator from it's attachment to the HVAC module case. Notice: The mode door arm is plastic. Care must be taken to avoid damaging the mode door arm. 5. Disconnect the mode door actuator from the mode door arm. 6. Install the new mode valve actuator, P/N 52487750 (this is replacing P/N 52487554), to the mode valve actuator arm and snap into place on the HVAC module case. 7. Connect the vacuum lines to the actuator. 8. Install the driver's knee bolster. 9. Tighten Tighten the screws to 2 Nm (18 lb in). 10. Install the left side instrument panel sound insulator panel. Parts Information Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 00-01-38-003A > Jan > 01 > Heating/AC - Popping Noise From Dash Area > Page 9552 Warranty Information For vehicles repaired under warranty, use the table. DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 9553 Air Door Actuator / Motor: Specifications Temperature Actuator Bolts 1.5 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations Air Door Actuator / Motor: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations > Page 9556 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations > Page 9557 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Connector Views Air Door Actuator / Motor: Connector Views Temperature Control Actuator Motor, LH Temperature Control Actuator Motor, RH Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Connector Views > Page 9560 Air Door Actuator / Motor: Vacuum and Vapor Hose Diagrams Vacuum Controls-RPO C60 HVAC Air Delivery/Temperature Control Schematics: Vacuum Controls RPO C60: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Connector Views > Page 9561 Vacuum Controls-RPO CJ3 HVAC Air Delivery/Temperature Control Schematics: Vacuum Controls RPO CJ3: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet Actuator Replacement Air Door Actuator / Motor: Service and Repair Air Inlet Actuator Replacement REMOVAL PROCEDURE 1. Remove the right instrument panel insulator. 2. Remove the instrument panel compartment. 3. Disconnect the vacuum line from the air inlet vacuum actuator. 4. Lift to release the air inlet vacuum actuator retaining tab and slide off mounting bracket. 5. Disconnect the vacuum actuator plunger rod from the air inlet valve lever and remove the vacuum actuator. INSTALLATION PROCEDURE 1. Connect the vacuum actuator plunger rod to the air inlet valve, then extend the plunger. IMPORTANT: During installation, ensure that the air inlet vacuum actuator retaining tab is positioned above the mating base on the HVAC module case. 2. Push the vacuum actuator toward the HVAC module case to secure the retaining tab. IMPORTANT: Check that the vacuum actuator pushrod is not binding on the air inlet lever. 3. Connect the vacuum harness connector to the air inlet vacuum actuator. 4. Install the instrument panel compartment. 5. Install the right instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet Actuator Replacement > Page 9564 Air Door Actuator / Motor: Service and Repair Defroster Actuator Replacement REMOVAL PROCEDURE 1. Remove the cross vehicle beam. 2. Disconnect the vacuum lines from the defroster vacuum actuator. 3. Rotate the defroster valve lever fully rearward (counterclockwise), then carefully insert a screw driver between the bottom of the defrost valve lever and the protruding wall of the HVAC module case below the valve lever in order to keep the valve lever in place. 4. Lift to release the defroster vacuum actuator retaining tab. 5. Carefully rotate the defroster vacuum actuator upward and forward to remove from the HVAC module case. 6. Disconnect the vacuum actuator pushrod from the defrost valve lever and remove the vacuum actuator. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet Actuator Replacement > Page 9565 1. Connect the vacuum actuator pushrod to the defrost valve lever. 2. Carefully rotate rearward and downward to align actuator slots with HVAC module case and push the vacuum actuator toward the HVAC module to secure the retaining tab. 3. Connect the vacuum lines to the defroster vacuum actuator. 4. Install the cross vehicle beam. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet Actuator Replacement > Page 9566 Air Door Actuator / Motor: Service and Repair Mode Actuator Replacement REMOVAL PROCEDURE 1. Remove the left instrument panel insulator. 2. Remove the instrument panel driver knee bolster. 3. Cut the tie strap (1) on the back side of the mode valve vacuum actuator. 4. Remove the vacuum lines from the mode valve vacuum actuator. 5. Carefully rotate the mode vacuum actuator towards the front of the vehicle until the actuator is released from the mounting pins on the HVAC module. 6. Disconnect the vacuum actuator pushrod from the mode valve lever and remove the actuator. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet Actuator Replacement > Page 9567 1. Connect the vacuum actuator push rod from the mode valve lever and position the actuator. 2. Carefully rotate the mode vacuum actuator towards the rear of the vehicle until the actuator is engaged on the mounting pins on the HVAC module. 3. Install the instrument panel driver knee bolster. 4. Install the left side instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet Actuator Replacement > Page 9568 Air Door Actuator / Motor: Service and Repair Temperature Actuator Replacement (LH) REMOVAL PROCEDURE 1. Remove the left instrument panel insulator. 2. Remove the knee bolster. 3. Disconnect the electrical connector from the temperature valve electric actuator. 4. Remove the mounting bolts from the temperature valve electric actuator. 5. Remove the temperature valve electric actuator. INSTALLATION PROCEDURE 1. Position the temperature valve electric actuator, then align the slots in the electric actuator driver to the flats on the temperature valve shaft. 2. Slide the electric actuator driver onto the shaft, while aligning the actuator locating hole to the forward alignment pin on the HVAC module case. The actuator driver should completely seat onto the temperature valve shaft and the mounting holes should be flush with the mounting bosses on the HVAC module case. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the mounting bolts to the temperature actuator. Tighten Tighten the temperature actuator bolts to 1.5 N.m (13 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet Actuator Replacement > Page 9569 4. Connect the electrical connector to the temperature actuator. 5. Install the knee bolster. 6. Install the left instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet Actuator Replacement > Page 9570 Air Door Actuator / Motor: Service and Repair Air Inlet Actuator Replacement REMOVAL PROCEDURE 1. Remove the right instrument panel insulator. 2. Remove the instrument panel compartment. 3. Disconnect the vacuum line from the air inlet vacuum actuator. 4. Lift to release the air inlet vacuum actuator retaining tab and slide off mounting bracket. 5. Disconnect the vacuum actuator plunger rod from the air inlet valve lever and remove the vacuum actuator. INSTALLATION PROCEDURE 1. Connect the vacuum actuator plunger rod to the air inlet valve, then extend the plunger. IMPORTANT: During installation, ensure that the air inlet vacuum actuator retaining tab is positioned above the mating base on the HVAC module case. 2. Push the vacuum actuator toward the HVAC module case to secure the retaining tab. IMPORTANT: Check that the vacuum actuator pushrod is not binding on the air inlet lever. 3. Connect the vacuum harness connector to the air inlet vacuum actuator. 4. Install the instrument panel compartment. 5. Install the right instrument panel insulator. Defroster Actuator Replacement REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet Actuator Replacement > Page 9571 1. Remove the cross vehicle beam. 2. Disconnect the vacuum lines from the defroster vacuum actuator. 3. Rotate the defroster valve lever fully rearward (counterclockwise), then carefully insert a screw driver between the bottom of the defrost valve lever and the protruding wall of the HVAC module case below the valve lever in order to keep the valve lever in place. 4. Lift to release the defroster vacuum actuator retaining tab. 5. Carefully rotate the defroster vacuum actuator upward and forward to remove from the HVAC module case. 6. Disconnect the vacuum actuator pushrod from the defrost valve lever and remove the vacuum actuator. INSTALLATION PROCEDURE 1. Connect the vacuum actuator pushrod to the defrost valve lever. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet Actuator Replacement > Page 9572 2. Carefully rotate rearward and downward to align actuator slots with HVAC module case and push the vacuum actuator toward the HVAC module to secure the retaining tab. 3. Connect the vacuum lines to the defroster vacuum actuator. 4. Install the cross vehicle beam. Mode Actuator Replacement REMOVAL PROCEDURE 1. Remove the left instrument panel insulator. 2. Remove the instrument panel driver knee bolster. 3. Cut the tie strap (1) on the back side of the mode valve vacuum actuator. 4. Remove the vacuum lines from the mode valve vacuum actuator. 5. Carefully rotate the mode vacuum actuator towards the front of the vehicle until the actuator is released from the mounting pins on the HVAC module. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet Actuator Replacement > Page 9573 6. Disconnect the vacuum actuator pushrod from the mode valve lever and remove the actuator. INSTALLATION PROCEDURE 1. Connect the vacuum actuator push rod from the mode valve lever and position the actuator. 2. Carefully rotate the mode vacuum actuator towards the rear of the vehicle until the actuator is engaged on the mounting pins on the HVAC module. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet Actuator Replacement > Page 9574 3. Install the instrument panel driver knee bolster. 4. Install the left side instrument panel insulator. Temperature Actuator Replacement (LH) REMOVAL PROCEDURE 1. Remove the left instrument panel insulator. 2. Remove the knee bolster. 3. Disconnect the electrical connector from the temperature valve electric actuator. 4. Remove the mounting bolts from the temperature valve electric actuator. 5. Remove the temperature valve electric actuator. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet Actuator Replacement > Page 9575 1. Position the temperature valve electric actuator, then align the slots in the electric actuator driver to the flats on the temperature valve shaft. 2. Slide the electric actuator driver onto the shaft, while aligning the actuator locating hole to the forward alignment pin on the HVAC module case. The actuator driver should completely seat onto the temperature valve shaft and the mounting holes should be flush with the mounting bosses on the HVAC module case. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the mounting bolts to the temperature actuator. Tighten Tighten the temperature actuator bolts to 1.5 N.m (13 lb in). 4. Connect the electrical connector to the temperature actuator. 5. Install the knee bolster. 6. Install the left instrument panel insulator. Temperature Actuator Replacement (RH) REMOVAL PROCEDURE 1. Remove the right side instrument panel insulator. 2. Remove the instrument panel compartment. 3. Disconnect the electrical connector from the temperature actuator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet Actuator Replacement > Page 9576 4. Remove the bolts retaining the temperature actuator. 5. Remove the temperature actuator. INSTALLATION PROCEDURE 1. Position the temperature actuator, then align the slots in the electric actuator driver to the flats on the temperature valve shaft. 2. Slide the electric actuator driver onto the shaft, while aligning the actuator locating holes to the forward alignment pin on the HVAC module case. The actuator driver should completely seat onto the temperature valve shaft and the mounting holes should be flush with the mounting bosses on the HVAC module case. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolts to the temperature valve electric actuator. Tighten Tighten the temperature actuator bolts to 1.5 N.m (13 lb in). 4. Connect the electrical connector to the temperature actuator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet Actuator Replacement > Page 9577 5. Install the instrument panel compartment. 6. Install the right side instrument panel insulator. Temperature Valve Replacement REMOVAL PROCEDURE 1. Remove the HVAC module. 2. Remove the LH temperature valve electric actuator. 3. Remove the RH temperature valve electric actuator, if equipped with CJ3. 4. Remove the air inlet housing retaining screws (1). 5. Remove the air inlet housing (2). 6. Remove the HVAC module upper mounting screws. 7. Release the retaining tab (1) and separate the upper and lower module halves. 8. Remove the HVAC module seal that is located between the upper and lower cases. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet Actuator Replacement > Page 9578 Start to remove the module case seal (blower motor side of case) seal (2) from the lower module case at the position shown (1). 9. Remove the temperature valve, if equipped with C60. IMPORTANT: The LH and RH temperature valves separate in the center. 10. Remove the temperature valves (1,2), if equipped with CJ3. Carefully pull the temperature valves apart in the center to remove the temperature valves from the HVAC module case. INSTALLATION PROCEDURE IMPORTANT: The LH and RH temperature valves pivot in the center. 1. Install the temperature valves (1,2), if equipped with CJ3. Carefully align the temperature valves into the HVAC module case. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet Actuator Replacement > Page 9579 2. Install the temperature valve, if equipped with C60. 3. Install the new case seal (2) into the HVAC module case (1). 4. Align and install the upper module case to the lower module case. Align and secure the retaining tab (1) on the upper module case to the retaining slot on the lower module case. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the HVAC module upper mounting screws. Tighten Tighten the HVAC module upper mounting screws to 1.5 N.m (13 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet Actuator Replacement > Page 9580 6. Install the air inlet housing (2). NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the air inlet housing retaining screws (1). Tighten Tighten the air inlet housing screws to 1.5 N.m (13 lb in). 8. Install the LH temperature valve electric actuator. 9. Install the RH temperature valve electric actuator, if equipped with CJ3. 10. Install the HVAC module. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications Air Duct: Specifications Air Distributor Case Cover Screws 1.5 Nm Air Duct Bolts 10 Nm Air Duct Center Screw 1.8 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Ducts Replacement - Auxiliary Air Duct: Service and Repair Air Distribution Ducts Replacement - Auxiliary REMOVAL PROCEDURE 1. Position aside the front half of the carpet. Refer to Carpet Replacement - Front in Interior Trim. 2. Remove the rear floor air outlet duct (1) from the holes in the floor reinforcement. 3. Disconnect the lower heater duct from the heater core outlet cover. 4. Remove the lower heater duct INSTALLATION PROCEDURE 1. Install the lower heat duct. 2. Connect the lower heater duct to the heater core outlet cover. 3. Position the rear floor air outlet duct (1) into the holes in the floor reinforcement. 4. Install the front carpet into position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Ducts Replacement - Auxiliary > Page 9586 Air Duct: Service and Repair Air Distributor Duct Replacement (IP/LH/Center) REMOVAL PROCEDURE 1. Remove the instrument panel (IP) trim pad. 2. Remove the LH/Center IP air duct retaining bolts. 3. Remove the LH/Center IP air duct from the cross vehicle beam. INSTALLATION PROCEDURE 1. Install the LH/Center air duct to the cross vehicle beam. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the air duct bolts. Tighten Tighten the air duct bolts to 10 N.m (89 lb in). 3. Install the instrument panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Ducts Replacement - Auxiliary > Page 9587 Air Duct: Service and Repair Air Distributor Duct Replacement (IP/RH) REMOVAL PROCEDURE 1. Remove the instrument panel (IP) trim pad. 2. Remove the IP RH air duct retaining bolts. 3. Remove the IP RH air duct from the cross vehicle beam. INSTALLATION PROCEDURE 1. Install the IP RH air duct to the cross vehicle beam. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the air duct bolts. Tighten Tighten the air duct bolts to 10 N.m (89 lb in). 3. Install the IP trim pad. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Ducts Replacement - Auxiliary > Page 9588 Air Duct: Service and Repair Air Distributor Duct Replacement (IP/RH/Defrost) REMOVAL PROCEDURE 1. Remove the cross vehicle beam. 2. Remove the RH/Defrost IP air duct retaining bolts and screw. 3. Remove the RH/Defrost IP air duct from the cross vehicle beam. INSTALLATION PROCEDURE 1. Install the RH/Defrost air duct to the cross vehicle beam. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the air duct center screw. Tighten Tighten the air duct center screw to 1.8 N.m (16 lb in). 3. Install the air duct bolts. Tighten Tighten the air duct bolts to 10 N.m (89 lb in). 4. Install the cross vehicle beam. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > Customer Interest for Air Register: > 06-01-39-010A > Jun > 08 > A/C - Horizontal Vent Louvers Loose or Inoperative Air Register: Customer Interest A/C - Horizontal Vent Louvers Loose or Inoperative TECHNICAL Bulletin No.: 06-01-39-010A Date: June 26, 2008 Subject: HVAC Horizontal Vent Louvers Loose or Inoperative (Reinstall Louver Tabs Into Thumbwheel/Deflector Housing) Models: 2000-2009 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-01-39-010 (Section 01 - HVAC). Condition Some customers may comment that when rotating the thumbwheel on the deflector vent, the horizontal vent louvers will not open or close properly. Cause This condition may be caused by the horizontal vent louver tabs becoming disengaged from the retaining holes in the thumbwheel actuator or the deflector housing. This causes the louvers to become inoperative or loose. The louvers are designed to move together in a uniform manner. Correction Shine a light into the deflector vent housing to determine if the inoperative louver still has two round tabs on one side and one round tab on the other side of the louver. If you are having difficulty seeing the tabs, it may be necessary to remove the inoperative louver. If the tabs are broken or the louver is missing, this bulletin does not apply. If all the round tabs are present, then proceed to reinstall the horizontal louver using the procedure below: Example of Deflector Vent with Louver Removed (Two Round Tabs on End of Louver Shown) Important: Depending on which louver you are working on, it may be necessary to have the louvers fully open but be careful not to drop the louver into the air duct. You may need a pair of needle-nose pliers to hold onto the louver when trying to position the two tabs into the thumbwheel and the housing pivot hole. 1. Start with the side thumbwheel in the down position and the horizontal louvers in the near closed position. 2. Install the two tabs of the louver into the thumbwheel actuator hole and the deflector housing pivot hole. 3. Bow the louver you are trying to reinstall outward towards you. 4. With the louver bowed, install the single tab into the opposite deflector housing pivot hole. 5. The louver may show a slight bow after installing. It may be necessary to straighten the louver by slightly bending the louver in the opposite position of the bow. 6. Verify the proper operation of the vent deflector louvers by using the thumbwheel control. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > Customer Interest for Air Register: > 06-01-39-010A > Jun > 08 > A/C - Horizontal Vent Louvers Loose or Inoperative > Page 9597 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Register: > 06-01-39-010A > Jun > 08 > A/C - Horizontal Vent Louvers Loose or Inoperative Air Register: All Technical Service Bulletins A/C - Horizontal Vent Louvers Loose or Inoperative TECHNICAL Bulletin No.: 06-01-39-010A Date: June 26, 2008 Subject: HVAC Horizontal Vent Louvers Loose or Inoperative (Reinstall Louver Tabs Into Thumbwheel/Deflector Housing) Models: 2000-2009 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-01-39-010 (Section 01 - HVAC). Condition Some customers may comment that when rotating the thumbwheel on the deflector vent, the horizontal vent louvers will not open or close properly. Cause This condition may be caused by the horizontal vent louver tabs becoming disengaged from the retaining holes in the thumbwheel actuator or the deflector housing. This causes the louvers to become inoperative or loose. The louvers are designed to move together in a uniform manner. Correction Shine a light into the deflector vent housing to determine if the inoperative louver still has two round tabs on one side and one round tab on the other side of the louver. If you are having difficulty seeing the tabs, it may be necessary to remove the inoperative louver. If the tabs are broken or the louver is missing, this bulletin does not apply. If all the round tabs are present, then proceed to reinstall the horizontal louver using the procedure below: Example of Deflector Vent with Louver Removed (Two Round Tabs on End of Louver Shown) Important: Depending on which louver you are working on, it may be necessary to have the louvers fully open but be careful not to drop the louver into the air duct. You may need a pair of needle-nose pliers to hold onto the louver when trying to position the two tabs into the thumbwheel and the housing pivot hole. 1. Start with the side thumbwheel in the down position and the horizontal louvers in the near closed position. 2. Install the two tabs of the louver into the thumbwheel actuator hole and the deflector housing pivot hole. 3. Bow the louver you are trying to reinstall outward towards you. 4. With the louver bowed, install the single tab into the opposite deflector housing pivot hole. 5. The louver may show a slight bow after installing. It may be necessary to straighten the louver by slightly bending the louver in the opposite position of the bow. 6. Verify the proper operation of the vent deflector louvers by using the thumbwheel control. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Register: > 06-01-39-010A > Jun > 08 > A/C - Horizontal Vent Louvers Loose or Inoperative > Page 9603 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > Page 9604 Air Register: Service and Repair Defroster Grille Replacement REMOVAL PROCEDURE 1. Remove the LH and the RH windshield pillar garnish moldings. 2. Starting at the RH side, carefully lift upwards on the defroster grille in order to release the retainers. Continue working to your left until all of the retainers are released. 3. Disconnect the daytime running lamps sensor from the defroster grille. 4. Remove the defroster grille. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > Page 9605 1. Position the defroster grille to the upper instrument panel (IP). Connect the daytime running lamps sensor to the defroster grille. Make sure the daytime running lamps sensor wiring harness will not be pinched when the defroster grille is installed. 2. Starting at the LH side, install the defroster grille retainers into the upper IP. Continue working to your right until all of the retainers are installed. 3. Install the RH and the LH windshield pillar garnish moldings. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Component Locations > Page 9610 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 9611 Ambient Outside Air Temperature Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 9612 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Temperature Sensor Replacement REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. 3. Disconnect the electrical connector from the ambient temperature sensor that is located on the front radiator air baffle. 4. Remove the ambient temperature sensor from the radiator air baffle. INSTALLATION PROCEDURE 1. Install the ambient temperature sensor to the radiator air baffle. 2. Connect the electrical connector to the ambient temperature sensor. 3. Lower the vehicle. 4. Connect the negative battery cable. 5. Drive the vehicle at a speed of 32 km/h (20 mph) for approximately one and a half minutes or at a speed of 72 km/h (45 mph) for approximately one minute in order to obtain the ambient update. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Blower Motor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9618 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9619 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9620 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9621 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9622 Auxiliary Blower Motor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9623 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9624 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9625 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9626 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9627 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9628 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9629 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9630 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9631 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9632 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9633 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9634 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9635 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9636 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9637 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9638 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9639 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9640 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9641 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9642 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9643 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations BLOWER MOTOR RELAY Locations View The Blower Motor Relay is located in the Blower Motor Control Module (Blower Resistor Assembly) and cannot be serviced separately. The Blower Motor Control Module (Blower Resistor Assembly) is located behind the Instrument Panel (IP), on the right side of the A/C module, attached to the blower motor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 9647 Blower Motor Relay: Description and Operation HVAC BLOWER CONTROLS CIRCUIT DESCRIPTION The blower motor is a variable speed motor. The motor operates at a higher rate when voltage is increased to the maximum level. The blower motor resistors reduce the voltage supplied from the A/C FAN fuse (LH IP Accessory Wiring Junction Block) when the blower control is set at low and medium speeds (speeds 1-4). The blower motor relay is energized when the Blower Motor Control is set to the High position. This removes the blower motor resistors from the circuit and battery voltage is then applied directly from the HVAC BLO fuse (RH IP Accessory Wiring Junction Block) to the blower motor though the relay switch contacts. The blower motor then runs at high speed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications Blower Motor Resistor: Specifications Blower Motor Resistor Bolts 1.5 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Component Locations > Page 9653 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor and Fan Replacement Blower Motor Resistor: Service and Repair Blower Motor and Fan Replacement REMOVAL PROCEDURE 1. Disconnect the battery negative cable. 2. Remove the right side instrument panel insulator. 3. Disconnect the blower motor electrical connector. 4. Disconnect the blower motor cooling hose. 5. Remove the blower motor mounting bolts. 6. Remove the blower motor. INSTALLATION PROCEDURE 1. Install the blower motor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor and Fan Replacement > Page 9656 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the blower motor bolts. Tighten Tighten the blower motor bolts to 1.3 N.m (12 lb in). 3. Connect the blower motor cooling hose. 4. Connect the blower motor electrical connector. 5. Install the right side instrument panel insulator. 6. Connect the battery negative cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor and Fan Replacement > Page 9657 Blower Motor Resistor: Service and Repair Blower Motor Resistor Replacement REMOVAL PROCEDURE 1. Disconnect the battery negative cable. 2. Remove the right side instrument panel insulator. 3. Disconnect the electrical connectors from the blower motor resistor. 4. Disconnect the blower motor resistor electrical connector from the blower motor. 5. Loosen, do not remove, both forward screws. The blower motor resistor opening is slotted as access is extremely limited. 6. Remove the rearward screw. 7. Remove the blower motor resistor. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor and Fan Replacement > Page 9658 1. Install the blower motor resistor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rearward bolt. Tighten Tighten the blower motor resistor bolt to 1.5 N.m (13 lb in). 3. Install both forward bolts. Tighten Tighten the blower motor resistor bolts to 1.5 N.m (13 lb in). 4. Connect the electrical connector to the blower motor. 5. Connect the electrical connector to the blower motor resistor. 6. Install the right side instrument panel insulator. 7. Connect the battery negative cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations > Page 9662 Cabin Air Filter: Description and Operation The filters have a 12 months or 20,000 km (15,000 miles) change interval. These filters may require frequent change intervals depending on driving conditions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations > Page 9663 Cabin Air Filter: Service and Repair PASSENGER COMPARTMENT AIR FILTER REPLACEMENT (IF EQUIPPED) REMOVAL PROCEDURE 1. Position the windshield wipers in the UP position, by keying the ignition OFF when the wiper reach the desired position. 2. Raise the hood. 3. Position aside the rear hood seal halfway to the center. Refer to Seal Replacement - Hood Rear in Body Front End. 4. Remove the right air inlet grill. 5. Remove the passenger compartment air filter. INSTALLATION PROCEDURE 1. Install the passenger compartment air filter. 2. Install the air inlet grill. Refer to Air Inlet Grille Panel Replacement in Body Front End. 3. Install the rear hood seal. 4. Close the hood. 5. Return the windshield wipers to the PARK position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Open the rear compartment. 2. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement (Impala) (See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair)Rear Bumper Fascia Replacement (Monte Carlo) (See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair) in Bumpers. 3. Pull back the rear compartment trim panel. 4. Apply pressure at 2 upper locations and 2 lower locations, using a small, flat-bladed tool in order to release the retainers on the pressure relief valve. 5. Remove the pressure relief valve from the lower quarter panel. Installation Procedure 1. Install the pressure relief valve to the lower quarter panel. 2. Press the pressure relief valve into the quarter lower panel until the retainers lock into place at the upper and lower locations. 3. Pull back the rear compartment trim panel. 4. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement (Impala) (See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair)Rear Bumper Fascia Replacement (Monte Carlo) (See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair) in Bumpers. 5. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Compressor Clutch Gap V5 Conventional Mount ....................................................................................................................... ..................................................... 0.40 - 0.50 mm V5 Direct Mount .................................................... .............................................................................................................................................. 0.40 mm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 9671 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > V5 - Conventional Mount Compressor Clutch: Service and Repair V5 - Conventional Mount Compressor Clutch Plate and Hub Assembly Removal TOOLS REQUIRED ^ J 33022 6-Point 13 mm Socket ^ J 33027-A Clutch Hub Holding Tool ^ J 33013-B Hub And Drive Plate Remover And Installer ^ J 34992 Compressor Holding Fixture 1. Clamp the J 34992 in a vise. 2. Attach the compressor to the holding fixture using the thumb screws. 3. Use the J 33027-A in order to prevent the clutch hub and drive plate assembly from turning. 4. Use the J 33022 in order to remove the shaft nut. 5. Thread the J 33013-B into the hub. 6. Use a wrench in order to hold the body of the J 33013-B. 7. Turn the center screw into the body of the J 33013-B in order to remove the clutch plate and hub assembly. 8. Remove the shaft key. Retain the shaft key for reassembly. Compressor Clutch Plate/Hub Assembly Install TOOLS REQUIRED ^ J 33013-B Hub And Drive Plate Remover And Installer ^ J 33022 Shaft Nut Socket ^ J 33027-A Clutch Hub Holding Tool ^ J 34992 Compressor Holding Fixture Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > V5 - Conventional Mount > Page 9674 1. Install the compressor into the J 34992. 2. Install the shaft key (4) into the key groove of the clutch plate and hub (1). ^ Allow the key to project 3.2 mm (0.126 in) out of the key groove. ^ The shaft key is curved slightly in order to provide an interference fit in the key groove of the hub. 3. Clean the frictional surfaces of the clutch plate and hub and the clutch pulley rotor (2). 4. Align the shaft key with the shaft keyway (3). NOTE: Do not drive or pound on the clutch hub or the shaft. Internal damage to the compressor may result. 5. Place the clutch plate and hub assembly onto the compressor shaft. 6. Remove the center screw from the J 33013-B. 7. Reverse the body direction of the center screw of the J 33013-B. 8. Install the J 33013-B with the bearing. 9. Back off the body of the J 33013-B in order to allow the center screw to be threaded onto the end of the compressor shaft. 10. Hold the center screw of the J 33013-B with a wrench. NOTE: If the center screw is threaded fully onto the end of the compressor shaft, or if the body of the installer is held and the center screw is rotated, the key will wedge and will break the clutch hub. 11. Tighten the hex portion of the body of the J 33013-B in order to press the hub onto the shaft. 12. Tighten the body of the J 33013-B several turns. 13. Remove the J 33013-B. 14. Verify that the shaft key remains in the keyway before installing the clutch plate and hub assembly to the final position. 15. Ensure that the gap between the frictional surfaces of the clutch plate and the clutch rotor is within 0.40-0.50 mm (0.016-0.020 in). 16. Remove the J 33013-B. 17. Verify that the shaft key is even with or slightly above the clutch hub. 18. Install the shaft nut. 19. Hold the clutch plate and hub assembly with the J 33027-A. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > V5 - Conventional Mount > Page 9675 20. Tighten the shaft nut against the crankshaft shoulder, using a 17.5 N.m (12.5 lb ft) torque wrench and the J 33022. Tighten Tighten the nut to 16.5 N.m (12 lb ft). 21. Spin the pulley rotor by hand in order to verify that the rotor does not rub the clutch drive plate. Clutch Rotor and/or Bearing Removal TOOLS REQUIRED ^ J 6083 Snap Ring Pliers #24 External ^ J 9398 Rotor Bearing Remover ^ J 8092 Driver Handle ^ J 33020 Pulley Puller ^ J 33023-A Puller Pilot 1. Remove the clutch plate and hub assembly. 2. Use the J 6083 in order to remove the rotor and bearing assembly retaining ring. 3. Install the J 33023-A to the front head. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > V5 - Conventional Mount > Page 9676 4. Install the J 33020 into the inner circle of slots in the rotor. 5. Turn the J 33020 clockwise in the slots in order to engage the tangs of the puller with the segments between the slots in the rotor. 6. Hold the J 33020 in place. Tighten the puller screw against the puller guide in order to remove the puller rotor and bearing assembly. 7. Support the rotor hub in order to prevent damage to the pulley rotor during bearing removal. 7.1. Remove the forcing screw from the J 33020. 7.2. With the tangs of the J 33020 still engaged in the rotor slots, invert the assembly onto a solid, flat surface or blocks. NOTE: It is not necessary to remove the staking in front of the bearing to remove the bearing, however, it will be necessary to file away the old stake metal for proper clearance for the new bearing to be installed into the rotor bore or the bearing may be damaged. 8. Use a J 9398 with the J 8092 in order to drive the bearing out of the rotor hub. Clutch Rotor and/or Bearing Install TOOLS REQUIRED ^ J 6083 Snap Ring Pliers ^ J 8092 Driver Handle ^ J 8433-1 Puller Bar ^ J 8433-3 Forcing Screw ^ J 9481-A Bearing Installer ^ J 21352-A Support Block ^ J 33017 Pulley And Bearing Assembly Installer ^ J 33019 Bearing Staking Tool ^ J 33023-A Puller Pilot ^ J 34992 Compressor Holding Fixture NOTE: Do not support the rotor by resting the pulley rim on a flat surface during the bearing installation or the rotor face will be bent. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > V5 - Conventional Mount > Page 9677 1. Place the pulley rotor on the J 21352-A in order to fully support the rotor hub during the bearing installation. 2. Align the new bearing with the hub bore. 3. Using the J 9481-A and the J 8092, drive the bearing into the hub. The J 9481-A applies force to the outer race of the bearing. 4. Place the J 33019 and the staking pin in the hub bore. 5. Shift the rotor and bearing assembly on the J 21352-A in order to fully support of the hub under the location of the staking pin. 6. Use a heavy-duty rubber band (1) in order to hold the stake pin in the guide of the J 33019. IMPORTANT: Do not allow a metal stake to contact the outer face of the bearing in order to prevent distortion of the outer race. 7. Using care in order to prevent injury, strike the staking pin of the J 33019. Properly position the stake pin in the guide after each impact on the pin. 8. Continue to strike the pin of the J 33019 until a stake, similar to the original stake, is formed down to, but not touching, the bearing. 9. Stake three places 120 degrees apart. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > V5 - Conventional Mount > Page 9678 10. With the compressor mounted to the J 34992, position the rotor and bearing assembly on the front head. 11. Position the J 33017 and the J 33023-A directly over the inner race of the bearing. 12. Position the J 8433-1 on the J 33023-A. 13. Assemble the two through bolts and the washers of the J 34992 through the slots of the J 8433-1. 14. Thread the two through bolts into the J 34992. Ensure that the thread of the through bolts engages the full thickness of the J 34992. 15. Tighten the J 8433-3 in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the front head of the compressor. 16. If the J 33017 slips off direct, in-line contact with inner face of the bearing, use the following steps: 16.1. Loosen the J 8433-3. 16.2. Realign the J 33017 and the J 33023-A in order to ensure that the installer clears the front head. 17. Install the rotor and bearing assembly retainer ring using the J 6083. 18. Install the clutch plate and hub assembly. Compressor Leak Testing ^ J 39400-A Electronic Halogen Leak Detector ^ J 39500-B A/C Refrigerant Recovery, Recycling and Recharging (ACR4) System ^ J 39893 Pressure Testing Connector Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > V5 - Conventional Mount > Page 9679 1. With the sealing washers in place, install the J 39893 on the rear head of the compressor. 2. Connect the gage charging lines and the J 39500-B. 3. Pressurize the suction and the high-side of the compressor using R-134a refrigerant. 4. With the compressor in a horizontal position, rotate the compressor shaft several turns by hand in the operating direction. 5. Using the J 39400-A, inspect for leaks at the following locations: ^ The pressure relief valve ^ The rear head switch ^ The front head seal ^ The rear head seal ^ The through bolt head gaskets ^ The compressor shaft seal 6. Perform the measures necessary to correct any external leaks found. 7. Inspect for leaks again following any repair. 8. Recover the refrigerant. 9. Disconnect the hoses from the J 39893. 10. Remove the J 39893. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > V5 - Conventional Mount > Page 9680 Compressor Clutch: Service and Repair V5 - Direct Mount Compressor Clutch Plate and Hub Assembly Removal TOOLS REQUIRED ^ J 33027-A Clutch Hub Holding Tool ^ J 33013-B Hub and Drive Plate Installer ^ J 41790 Compressor Holding Fixture 1. Clamp the J 41790 in a vise and attach the compressor to the holding fixture. 2. Hold the clutch hub and drive plate assembly (2) in place using the J 33027-A. 3. Remove the compressor shaft nut with a 13 mm socket (1). 4. Thread the clutch plate and hub remover and installer tool hub and drive plate installer into the hub. 5. Remove the hub and drive plate assembly (1) by turning the center screw into the body of the hub and drive plate installer and against the compressor shaft. 6. Remove the shaft key and retain for reassembly. Compressor Clutch Plate/Hub Assembly Install TOOLS REQUIRED ^ J 33013-B Hub and Drive Plate Installer ^ J 33027-A Clutch Hub Holding Tool ^ J 33017 Pulley and Bearing Assembly Installer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > V5 - Conventional Mount > Page 9681 1. Install the shaft key into the hub key groove (4) approximately 3.2 mm (1/8 in) out of the keyway. The shaft key is curved slightly to provide an interference fit in the hub key groove. 2. Clean the surfaces of the clutch plate (1) and the clutch rotor (2) before installing the clutch plate and hub assembly. 3. Align the shaft key with the shaft keyway in the clutch plate and the hub assembly and place onto the compressor shaft (3). 4. Remove the J 33013-B. 4.1. Remove the center screw from the body of the hub and drive plate installer. 4.2. Install the center screw into the opposite end of the hub and drive plate installer. 5. Install the J 33013-B and bearing tools (1) onto the clutch plate (3) and the hub assembly (2). 5.1. Back the body of the hub and drive plate installer tool off enough to allow the center screw to be threaded onto the end of the compressor shaft. 5.2. Thread the center screw several turns onto the end of the compressor shaft. Do not tighten the center screw on the compressor shaft. 6. Hold the center screw with a wrench. 6.1. Tighten the hex portion of the hub and drive plate installer body several turns. 6.2. Remove the hub and drive plate installer from the clutch plate and hub. 6.3. Make sure that the shaft key is still in place in the keyway. 7. Reinstall the J 33013-B. 8. Place a feeler gauge between the clutch plate and the clutch rotor. 9. Tighten the hex portion of the hub and drive plate installer until the air gap between the clutch plate and clutch rotor is 0.40 mm (0.015 in). Make sure that the air gap is even all around the clutch plate and hub assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > V5 - Conventional Mount > Page 9682 10. Remove the J 33013-B. 11. Hold the clutch plate and hub assembly (2) with the J 33027-A. NOTE: Refer to Fastener Notice in Service Precautions. 12. Install the compressor shaft nut. Tighten Tighten the compressor shaft nut to 17 N.m (13 lb ft). 13. Spin the pulley rotor by hand to make sure the rotor is not rubbing against the clutch drive plate. 14. Remove the compressor from the J 41790. Clutch Rotor and/or Bearing Removal TOOLS REQUIRED ^ J 41790 Compressor Holding Fixture ^ J 41552 Compressor Pulley Puller ^ J 33023-A Puller Pilot 1. Install the compressor onto the J 41790. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > V5 - Conventional Mount > Page 9683 2. Remove the clutch plate and hub assembly (2). 3. Remove the clutch rotor and bearing assembly retaining ring (3), using external snap ring pliers (1). 4. Place the J 33023-A on the clutch rotor. 5. Install the J 41552 down into the inner circle of slots in the rotor. Turn the compressor pulley puller clockwise in the slots to engage the puller tangs with the rotor. 6. Hold the compressor pulley puller in place and use a wrench to turn the center forcing screw against the puller pilot to remove the clutch rotor and bearing assembly. Clutch Rotor and/or Bearing Install TOOLS REQUIRED ^ J 33013-B Hub and Drive Plate Installer ^ J 33017 Pulley and Bearing Assembly Installer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > V5 - Conventional Mount > Page 9684 ^ J 41790 Compressor Holding Fixture ^ J 42126 Tool Kit 1. Position the clutch rotor and bearing assembly (2) onto the compressor. 2. Position the J 33017 and bearing (1) from the J 33013-B directly over the inner race of the bearing. 3. Place the washer (3) from the J 42126 tool kit onto the body of J 33013-B. 4. Remove the center screw from the body of the hub and drive plate installer. 5. Install the center screw into the opposite end of the hub and drive plate installer. 6. Back the body of the hub and drive plate installer tool off enough to allow the center screw to be threaded onto the end of the compressor shaft. 7. Thread the center screw several turns onto the end of the compressor shaft. Do not tighten the center screw on the compressor shaft. 8. Hold the center screw with a wrench. 9. Tighten the hex portion of the hub and drive plate installer body several turns. 10. Remove the J 33013-B from the clutch rotor and bearing assembly. 11. Ensure that the clutch rotor and bearing (2) is pressed onto the nose of the compressor far enough to clear the groove for the retaining ring. If the clutch rotor and bearing does not clear the groove, repeat steps 7, 8 and 9. 12. Install the clutch rotor and bearing retaining ring (3) using external snap ring pliers (1). Ensure that the chamfer side of the retaining ring is facing up when the retaining ring is being installed. 13. Install the clutch plate and hub assembly. 14. Remove the compressor from the J 41790. Compressor Leak Testing TOOLS REQUIRED ^ J 39400-A Leak Detector ^ J 39500-B R-134a Air Conditioning Refrigerant Recovery, Recycling And Recharging System ^ J 39893 Pressure Testing Connector Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > V5 - Conventional Mount > Page 9685 1. With the sealing washers in place, install the J 39893 on the rear head of the compressor. 2. Connect the gage charging lines and the J 39500-B. 3. Pressurize the suction and the high-side of the compressor with R-134a refrigerant. 4. With the compressor in a horizontal position, rotate by hand the compressor shaft in the operating direction. 5. Rotate the shaft several times. 6. Using the J 39400-A, check for leaks at the following locations: ^ Pressure relief valve ^ Rear head switch ^ Front head seals ^ Rear head seals ^ Through bolt head gaskets ^ Compressor shaft seal 7. Perform the measures necessary to correct any external leaks found. 8. Recheck for leaks following any repair. 9. Recover the refrigerant. 10. Disconnect the hoses from the J 39893. 11. Remove the J 39893. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal (V5 - Conventional Mount) Compressor Clutch Bearing: Service and Repair Clutch Rotor and/or Bearing Removal (V5 Conventional Mount) TOOLS REQUIRED ^ J 6083 Snap Ring Pliers #24 External ^ J 9398 Rotor Bearing Remover ^ J 8092 Driver Handle ^ J 33020 Pulley Puller ^ J 33023-A Puller Pilot 1. Remove the clutch plate and hub assembly. 2. Use the J 6083 in order to remove the rotor and bearing assembly retaining ring. 3. Install the J 33023-A to the front head. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal (V5 - Conventional Mount) > Page 9690 4. Install the J 33020 into the inner circle of slots in the rotor. 5. Turn the J 33020 clockwise in the slots in order to engage the tangs of the puller with the segments between the slots in the rotor. 6. Hold the J 33020 in place. Tighten the puller screw against the puller guide in order to remove the puller rotor and bearing assembly. 7. Support the rotor hub in order to prevent damage to the pulley rotor during bearing removal. 7.1. Remove the forcing screw from the J 33020. 7.2. With the tangs of the J 33020 still engaged in the rotor slots, invert the assembly onto a solid, flat surface or blocks. NOTE: It is not necessary to remove the staking in front of the bearing to remove the bearing, however, it will be necessary to file away the old stake metal for proper clearance for the new bearing to be installed into the rotor bore or the bearing may be damaged. 8. Use a J 9398 with the J 8092 in order to drive the bearing out of the rotor hub. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal (V5 - Conventional Mount) > Page 9691 Compressor Clutch Bearing: Service and Repair Clutch Rotor and/or Bearing Removal (V5 - Direct Mount) TOOLS REQUIRED ^ J 41790 Compressor Holding Fixture ^ J 41552 Compressor Pulley Puller ^ J 33023-A Puller Pilot 1. Install the compressor onto the J 41790. 2. Remove the clutch plate and hub assembly (2). 3. Remove the clutch rotor and bearing assembly retaining ring (3), using external snap ring pliers (1). 4. Place the J 33023-A on the clutch rotor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal (V5 - Conventional Mount) > Page 9692 5. Install the J 41552 down into the inner circle of slots in the rotor. Turn the compressor pulley puller clockwise in the slots to engage the puller tangs with the rotor. 6. Hold the compressor pulley puller in place and use a wrench to turn the center forcing screw against the puller pilot to remove the clutch rotor and bearing assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal (V5 - Conventional Mount) > Page 9693 Compressor Clutch Bearing: Service and Repair Clutch Rotor and/or Bearing Install (V5 Conventional Mount) TOOLS REQUIRED ^ J 6083 Snap Ring Pliers ^ J 8092 Driver Handle ^ J 8433-1 Puller Bar ^ J 8433-3 Forcing Screw ^ J 9481-A Bearing Installer ^ J 21352-A Support Block ^ J 33017 Pulley And Bearing Assembly Installer ^ J 33019 Bearing Staking Tool ^ J 33023-A Puller Pilot ^ J 34992 Compressor Holding Fixture NOTE: Do not support the rotor by resting the pulley rim on a flat surface during the bearing installation or the rotor face will be bent. 1. Place the pulley rotor on the J 21352-A in order to fully support the rotor hub during the bearing installation. 2. Align the new bearing with the hub bore. 3. Using the J 9481-A and the J 8092, drive the bearing into the hub. The J 9481-A applies force to the outer race of the bearing. 4. Place the J 33019 and the staking pin in the hub bore. 5. Shift the rotor and bearing assembly on the J 21352-A in order to fully support of the hub under the location of the staking pin. 6. Use a heavy-duty rubber band (1) in order to hold the stake pin in the guide of the J 33019. IMPORTANT: Do not allow a metal stake to contact the outer face of the bearing in order to prevent distortion of the outer race. 7. Using care in order to prevent injury, strike the staking pin of the J 33019. Properly position the stake pin in the guide after each impact on the pin. 8. Continue to strike the pin of the J 33019 until a stake, similar to the original stake, is formed down to, but not touching, the bearing. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal (V5 - Conventional Mount) > Page 9694 9. Stake three places 120 degrees apart. 10. With the compressor mounted to the J 34992, position the rotor and bearing assembly on the front head. 11. Position the J 33017 and the J 33023-A directly over the inner race of the bearing. 12. Position the J 8433-1 on the J 33023-A. 13. Assemble the two through bolts and the washers of the J 34992 through the slots of the J 8433-1. 14. Thread the two through bolts into the J 34992. Ensure that the thread of the through bolts engages the full thickness of the J 34992. 15. Tighten the J 8433-3 in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the front head of the compressor. 16. If the J 33017 slips off direct, in-line contact with inner face of the bearing, use the following steps: 16.1. Loosen the J 8433-3. 16.2. Realign the J 33017 and the J 33023-A in order to ensure that the installer clears the front head. 17. Install the rotor and bearing assembly retainer ring using the J 6083. 18. Install the clutch plate and hub assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal (V5 - Conventional Mount) > Page 9695 Compressor Clutch Bearing: Service and Repair Clutch Rotor and/or Bearing Install (V5 - Direct Mount) TOOLS REQUIRED ^ J 33013-B Hub and Drive Plate Installer ^ J 33017 Pulley and Bearing Assembly Installer ^ J 41790 Compressor Holding Fixture ^ J 42126 Tool Kit 1. Position the clutch rotor and bearing assembly (2) onto the compressor. 2. Position the J 33017 and bearing (1) from the J 33013-B directly over the inner race of the bearing. 3. Place the washer (3) from the J 42126 tool kit onto the body of J 33013-B. 4. Remove the center screw from the body of the hub and drive plate installer. 5. Install the center screw into the opposite end of the hub and drive plate installer. 6. Back the body of the hub and drive plate installer tool off enough to allow the center screw to be threaded onto the end of the compressor shaft. 7. Thread the center screw several turns onto the end of the compressor shaft. Do not tighten the center screw on the compressor shaft. 8. Hold the center screw with a wrench. 9. Tighten the hex portion of the hub and drive plate installer body several turns. 10. Remove the J 33013-B from the clutch rotor and bearing assembly. 11. Ensure that the clutch rotor and bearing (2) is pressed onto the nose of the compressor far enough to clear the groove for the retaining ring. If the clutch rotor and bearing does not clear the groove, repeat steps 7, 8 and 9. 12. Install the clutch rotor and bearing retaining ring (3) using external snap ring pliers (1). Ensure that the chamfer side of the retaining ring is facing up when the retaining ring is being installed. 13. Install the clutch plate and hub assembly. 14. Remove the compressor from the J 41790. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams A/C Compressor Clutch Coil Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 9699 Compressor Clutch Coil: Description and Operation The compressor clutch coil is energized through the compressor control relay. This relay is activated by the PCM in A/C modes. The PCM provides cut-off of the relay under certain operating conditions, including wide open throttle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal (V5 - Conventional Mount) Compressor Clutch Coil: Service and Repair Compressor Clutch Coil Removal (V5 - Conventional Mount) TOOLS REQUIRED ^ J 6083 Snap Ring Pliers ^ J 8433-1 Puller Bar ^ J 8433-3 Forcing Screw ^ J 33020 Pulley Puller ^ J 33023-A Puller Pilot ^ J 33025 Clutch Coil Puller Legs 1. Remove the clutch plate and hub assembly. 2. Use the J 6083 in order to remove the rotor and bearing assembly retaining ring. 3. Install the J 33023-A to the front head. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal (V5 - Conventional Mount) > Page 9702 4. Install the J 33020 into the inner circle of slots in the rotor. 5. Turn the J 33020 clockwise in the slots in order to engage the tangs of the puller with the segments between the slots in the rotor. 6. Hold the J 33020 in place. Tighten the puller screw against the puller guide in order to remove the puller rotor and bearing assembly. 7. Mark the location of the clutch coil terminal (1) on the compressor front head. 8. Install the J 33023-A on the front head of the compressor. 9. Install the J 8433-1 and the J 8433-3 with the J 33025 on the front head of the compressor. 10. Tighten the J 8433-3 against the J 33023-A in order to remove the clutch coil (2). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal (V5 - Conventional Mount) > Page 9703 Compressor Clutch Coil: Service and Repair Compressor Clutch Coil Removal (V5 - Direct Mount) TOOLS REQUIRED ^ J 41790 Compressor Holding Fixture ^ J 8433 Compressor Pulley Puller ^ J 8433-3 Forcing Screw J 33025 Clutch Coil Puller Legs ^ J 33023-A Puller Pilot 1. Install the compressor onto the J 41790. 2. Install the J 33023-A onto the front head of the compressor. 3. Remove the compressor clutch plate and hub assembly. 4. Remove the compressor rotor and bearing assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal (V5 - Conventional Mount) > Page 9704 5. Mark the clutch coil terminal location (2) on the compressor front head. 6. Install the J 33025 onto the J 8433. 7. Install the J 8433 onto the compressor clutch coil (1) and tighten the puller leg bolts. 8. Tighten the center forcing screw J 8433-3 of the compressor pulley puller J 8433 against the puller pilot to remove the compressor clutch coil from the compressor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal (V5 - Conventional Mount) > Page 9705 Compressor Clutch Coil: Service and Repair Compressor Clutch Coil Install (V5 - Conventional Mount) TOOLS REQUIRED ^ J 8433-1 Puller Bar ^ J 8433-3 Forcing Screw ^ J 33024 Clutch Coil Installer ^ J 34992 Compressor Holding Fixture ^ J 33025 Clutch Coil Puller Legs 1. Place the clutch coil assembly on the front head with the terminals positioned at the marked location. 2. Place the J 33024 over the internal opening of the clutch coil housing. 3. Align the J 33024 with the compressor front head. 4. Center the J 8433-1 on the countersunk center hole of the J 33024. 5. Install the through bolts and the washers of the J 34992 through the slots in the J 8433-1. 6. Thread the through bolts into the J 33025 in order to achieve full fixture thickness. IMPORTANT: Ensure that the clutch coil and the J 33024 stay in-line during the installation. 7. Turn the J 8433-3 of the J 8433-1 in order to force the clutch coil onto the head. 8. With the compressor still mounted to the J 34992 and the coil seated on the front head, stake the front head using a drift punch with a diameter of 3.175 mm (0.125 in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal (V5 - Conventional Mount) > Page 9706 9. Stake the front head at 3 places 120 degrees apart in order to ensure that the clutch coil remains in position. 10. Ensure that the stake size is only one half of the area of the punch tip and only 0.28-0.35 mm (0.010-0.015 in) in depth. 11. With the compressor mounted to the J 34992, position the rotor and bearing assembly on the front head. 12. Position the J 33017 and the J 33023-A directly over the inner race of the bearing. 13. Position the J 8433-1 on the J 33023-A. 14. Assemble the two through bolts and the washers of the J 34992 through the slots of the J 8433-1. 15. Thread the two through bolts into the J 34992. Ensure that the thread of the through bolts engages the full thickness of the J 34992. 16. Tighten the J 8433-3 in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the front head of the compressor. 17. If the J 33017 slips off direct, in-line contact with inner face of the bearing, use the following steps: 17.1. Loosen the J 8433-3. 17.2. Realign the J 33017 and the J 33023-A in order to ensure that the installer clears the front head. 18. Install the rotor and bearing assembly retainer ring using the J6083. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal (V5 - Conventional Mount) > Page 9707 19. Install the clutch plate and hub assembly. 20. Install the shaft nut. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal (V5 - Conventional Mount) > Page 9708 Compressor Clutch Coil: Service and Repair Compressor Clutch Coil Install (V5 - Direct Mount) TOOLS REQUIRED ^ J 33024 Clutch Coil Installer Adaptor ^ J 33025 Clutch Coil Puller Legs ^ J 8433 Compressor Pulley Puller ^ J 8433-3 Forcing Screw ^ J 41790 Compressor Holding Fixture 1. Place the clutch coil assembly (1) on the front head with the clutch coil terminal at the positioned at the mark made during disassembly. 2. Place the J 33024 over the internal opening of the clutch coil housing and align installer with the compressor front head. 3. Install the J 8433-3 into the J 8433 and center the screw in the countersunk center hole of the J 33024. 4. Install the 4 inch through bolts and washers from the J 42136 tool kit into the J 33025 and attach them to the compressor mounting bosses. 5. Turn the center forcing screw of the J 8433 to press the clutch coil onto the front head until the clutch coil is fully seated. Make sure the clutch coil and the J 33024 stay in-line with each other while pressing the clutch coil onto the compressor. 6. Install the compressor clutch rotor and bearing assembly. 7. Install the compressor clutch plate and hub assembly. 8. Remove the compressor from the J 41790. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > V5 - Conventional Mount Compressor Clutch Hub: Service and Repair V5 - Conventional Mount Compressor Clutch Plate and Hub Assembly Removal TOOLS REQUIRED ^ J 33022 6-Point 13 mm Socket ^ J 33027-A Clutch Hub Holding Tool ^ J 33013-B Hub And Drive Plate Remover And Installer ^ J 34992 Compressor Holding Fixture 1. Clamp the J 34992 in a vise. 2. Attach the compressor to the holding fixture using the thumb screws. 3. Use the J 33027-A in order to prevent the clutch hub and drive plate assembly from turning. 4. Use the J 33022 in order to remove the shaft nut. 5. Thread the J 33013-B into the hub. 6. Use a wrench in order to hold the body of the J 33013-B. 7. Turn the center screw into the body of the J 33013-B in order to remove the clutch plate and hub assembly. 8. Remove the shaft key. Retain the shaft key for reassembly. Compressor Clutch Plate/Hub Assembly Install TOOLS REQUIRED ^ J 33013-B Hub And Drive Plate Remover And Installer ^ J 33022 Shaft Nut Socket ^ J 33027-A Clutch Hub Holding Tool ^ J 34992 Compressor Holding Fixture Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > V5 - Conventional Mount > Page 9713 1. Install the compressor into the J 34992. 2. Install the shaft key (4) into the key groove of the clutch plate and hub (1). ^ Allow the key to project 3.2 mm (0.126 in) out of the key groove. ^ The shaft key is curved slightly in order to provide an interference fit in the key groove of the hub. 3. Clean the frictional surfaces of the clutch plate and hub and the clutch pulley rotor (2). 4. Align the shaft key with the shaft keyway (3). NOTE: Do not drive or pound on the clutch hub or the shaft. Internal damage to the compressor may result. 5. Place the clutch plate and hub assembly onto the compressor shaft. 6. Remove the center screw from the J 33013-B. 7. Reverse the body direction of the center screw of the J 33013-B. 8. Install the J 33013-B with the bearing. 9. Back off the body of the J 33013-B in order to allow the center screw to be threaded onto the end of the compressor shaft. 10. Hold the center screw of the J 33013-B with a wrench. NOTE: If the center screw is threaded fully onto the end of the compressor shaft, or if the body of the installer is held and the center screw is rotated, the key will wedge and will break the clutch hub. 11. Tighten the hex portion of the body of the J 33013-B in order to press the hub onto the shaft. 12. Tighten the body of the J 33013-B several turns. 13. Remove the J 33013-B. 14. Verify that the shaft key remains in the keyway before installing the clutch plate and hub assembly to the final position. 15. Ensure that the gap between the frictional surfaces of the clutch plate and the clutch rotor is within 0.40-0.50 mm (0.016-0.020 in). 16. Remove the J 33013-B. 17. Verify that the shaft key is even with or slightly above the clutch hub. 18. Install the shaft nut. 19. Hold the clutch plate and hub assembly with the J 33027-A. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > V5 - Conventional Mount > Page 9714 20. Tighten the shaft nut against the crankshaft shoulder, using a 17.5 N.m (12.5 lb ft) torque wrench and the J 33022. Tighten Tighten the nut to 16.5 N.m (12 lb ft). 21. Spin the pulley rotor by hand in order to verify that the rotor does not rub the clutch drive plate. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > V5 - Conventional Mount > Page 9715 Compressor Clutch Hub: Service and Repair V5 - Direct Mount Compressor Clutch Plate and Hub Assembly Removal TOOLS REQUIRED ^ J 33027-A Clutch Hub Holding Tool ^ J 33013-B Hub and Drive Plate Installer ^ J 41790 Compressor Holding Fixture 1. Clamp the J 41790 in a vise and attach the compressor to the holding fixture. 2. Hold the clutch hub and drive plate assembly (2) in place using the J 33027-A. 3. Remove the compressor shaft nut with a 13 mm socket (1). 4. Thread the clutch plate and hub remover and installer tool hub and drive plate installer into the hub. 5. Remove the hub and drive plate assembly (1) by turning the center screw into the body of the hub and drive plate installer and against the compressor shaft. 6. Remove the shaft key and retain for reassembly. Compressor Clutch Plate/Hub Assembly Install TOOLS REQUIRED ^ J 33013-B Hub and Drive Plate Installer ^ J 33027-A Clutch Hub Holding Tool ^ J 33017 Pulley and Bearing Assembly Installer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > V5 - Conventional Mount > Page 9716 1. Install the shaft key into the hub key groove (4) approximately 3.2 mm (1/8 in) out of the keyway. The shaft key is curved slightly to provide an interference fit in the hub key groove. 2. Clean the surfaces of the clutch plate (1) and the clutch rotor (2) before installing the clutch plate and hub assembly. 3. Align the shaft key with the shaft keyway in the clutch plate and the hub assembly and place onto the compressor shaft (3). 4. Remove the J 33013-B. 4.1. Remove the center screw from the body of the hub and drive plate installer. 4.2. Install the center screw into the opposite end of the hub and drive plate installer. 5. Install the J 33013-B and bearing tools (1) onto the clutch plate (3) and the hub assembly (2). 5.1. Back the body of the hub and drive plate installer tool off enough to allow the center screw to be threaded onto the end of the compressor shaft. 5.2. Thread the center screw several turns onto the end of the compressor shaft. Do not tighten the center screw on the compressor shaft. 6. Hold the center screw with a wrench. 6.1. Tighten the hex portion of the hub and drive plate installer body several turns. 6.2. Remove the hub and drive plate installer from the clutch plate and hub. 6.3. Make sure that the shaft key is still in place in the keyway. 7. Reinstall the J 33013-B. 8. Place a feeler gauge between the clutch plate and the clutch rotor. 9. Tighten the hex portion of the hub and drive plate installer until the air gap between the clutch plate and clutch rotor is 0.40 mm (0.015 in). Make sure that the air gap is even all around the clutch plate and hub assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > V5 - Conventional Mount > Page 9717 10. Remove the J 33013-B. 11. Hold the clutch plate and hub assembly (2) with the J 33027-A. NOTE: Refer to Fastener Notice in Service Precautions. 12. Install the compressor shaft nut. Tighten Tighten the compressor shaft nut to 17 N.m (13 lb ft). 13. Spin the pulley rotor by hand to make sure the rotor is not rubbing against the clutch drive plate. 14. Remove the compressor from the J 41790. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Control Valve Assembly > Component Information > Service and Repair > V5 - Direct Mount Compressor Control Valve Assembly: Service and Repair V5 - Direct Mount Compressor Control Valve Assembly Removal TOOLS REQUIRED J 41790 Compressor Holding Fixture 1. Install the compressor onto the J 41790. 2. Remove the compressor control valve retaining ring using internal snap ring pliers. 3. Remove the compressor control valve from the compressor. Compressor Control Valve Assembly Install TOOLS REQUIRED J 41790 Compressor Holding Fixture 1. Coat the control valve O-rings with clean 525 viscosity refrigeration oil. 2. Push the compressor control valve into the compressor with thumb pressure. 3. Using internal snap ring pliers, install the compressor control valve retaining ring. Ensure that the retaining ring is properly seated in the ring groove. 4. Remove the compressor from the J 41790. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Control Valve Assembly > Component Information > Service and Repair > V5 - Direct Mount > Page 9722 Compressor Control Valve Assembly: Service and Repair V5 - Conventional Mount Compressor Control Valve Assembly Removal TOOLS REQUIRED J 5403 Snap Ring Pliers 1. Remove the control valve retaining ring using the J 5403. 2. Remove the control valve assembly (5). Compressor Control Valve Assembly Install TOOLS REQUIRED J 5403 Snap Ring Pliers 1. Coat the O-rings with 525 viscosity refrigeration oil. 2. Using thumb pressure, push the O-rings in place. 3. Install the valve into the case. IMPORTANT: Ensure that the retaining ring is properly seated in the ring groove. 4. Using the J 5403, install the valve retaining ring (5) with the high point of the curved sides against the valve housing. 5. Evacuate the system. Recharge the system. 6. Perform a leak test. Refer to Compressor Leak Testing (V5 - Conventional Mount). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Compressor Shaft Seal Removal (V5 - Direct Mount) Compressor Shaft Seal: Service and Repair Compressor Shaft Seal Removal (V5 - Direct Mount) TOOLS REQUIRED ^ J 41790 Compressor Holding Tool ^ J 42136 A/C Lip Seal Remover 1. Place the compressor on the J 41790. 2. Remove the compressor clutch plate and hub assembly. 3. Remove the compressor shaft seal retainer ring (2), using internal snap ring pliers (1). 4. To keep any dirt or foreign material from getting into the compressor, thoroughly clean the following components: ^ The inside of the compressor neck area surrounding the shaft ^ The exposed portion of the compressor shaft seal ^ The compressor shaft ^ The O-ring groove Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Compressor Shaft Seal Removal (V5 - Direct Mount) > Page 9727 5. Fully engage the lip of the J 42136 into the recessed portion of the seal (1) then turn the handle clockwise. 6. Remove the compressor shaft seal from the compressor with a rotary pulling motion. 7. Recheck the shaft and inside of the compressor neck for dirt or foreign material and make sure these areas are perfectly clean before installing the new compressor shaft seal. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Compressor Shaft Seal Removal (V5 - Direct Mount) > Page 9728 Compressor Shaft Seal: Service and Repair Compressor Shaft Seal Removal (V5 - Conventional Mount) TOOLS REQUIRED ^ J 34992 Compressor Holding Fixture ^ J 39400-A Electronic Halogen Leak Detector ^ J 9553-01 O-ring Remover ^ J 5403 Snap Ring Pliers ^ J 23128-A Seal Seat Installer and Remover IMPORTANT: Do not change a shaft seal because of small amounts of oil found on an adjacent surface. The seal allows some oil to pass for lubrication purposes. Change the shaft seal when the following conditions exist: ^ A large amount of sprayed oil is found. ^ Actual refrigerant leak is found, using a J 39400-A or equivalent. 1. Install the compressor into the J 34992. 2. Remove the clutch plate and hub assembly. 3. Remove the shaft seal retaining ring using the J 5403. 4. In order to prevent dirt or foreign material from damaging the compressor, thoroughly clean the following parts: ^ The inside of the compressor neck area surrounding the shaft ^ The exposed portion of the seal ^ The compressor shaft ^ The O-ring groove IMPORTANT: Securely hand-tighten the handle of the J 23128-A. Do not use a wrench or pliers. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Compressor Shaft Seal Removal (V5 - Direct Mount) > Page 9729 5. Fully engage the knurled tangs of the J 23128-A into the recessed portion of the seal by turning the handle clockwise. 6. Remove the seal from the compressor using a rotary-pulling motion. Discard the seal. 7. Remove the seal O-ring from the compressor neck using the J 9553-01. Discard the seal O-ring. 8. Inspect the shaft and the inside of the compressor neck again for dirt and foreign material. 9. Ensure that the shaft and the inside of the compressor neck are perfectly clean prior to installing new parts. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Compressor Shaft Seal Removal (V5 - Direct Mount) > Page 9730 Compressor Shaft Seal: Service and Repair Compressor Shaft Seal Install (V5 - Direct Mount) TOOLS REQUIRED ^ J 34614 Shaft Seal Protector ^ J 41790 Compressor Holding Fixture ^ J 42136 A/C Lip Seal Remover 1. Dip the new compressor shaft seal (1) in clean 525 viscosity refrigerant oil and assemble the seal onto the J 42136, by turning the handle clockwise. 2. Install the J 34614 onto the compressor shaft. 3. Using a rotary motion, slide the new compressor shaft seal onto the compressor shaft until the seal is fully seated. 4. Remove the J 42136 by turning the handle counter clockwise. 5. Install a new compressor shaft seal retaining ring (2), using internal snap ring pliers (1). Ensure that the chamfer side of the retaining ring is facing up and that the retaining ring snaps into the groove. 6. Leak test the compressor. Refer to Compressor Leak Testing (V5 Direct Mount). 7. Remove and clean any excess oil resulting from installing the new seal parts from the shaft and inside the compressor neck. 8. Install the compressor clutch plate and hub assembly. 9. Remove the compressor from the J 41790. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Compressor Shaft Seal Removal (V5 - Direct Mount) > Page 9731 Compressor Shaft Seal: Service and Repair Compressor Shaft Seal Install (V5 - Conventional Mount) TOOLS REQUIRED ^ J 5403 Snap Ring Pliers ^ J 23128-A Seal Seat Installer And Remover ^ J 33011 O-ring Installer ^ J 34614 Shaft Seal Protector NOTE: Seals should not be re-used. Always use a new specification service seal kit. Be sure that the seal to be installed is not scratched or damaged in any way. Make sure that the seal is free of lint and din that could damage the seal surface or prevent sealing. 1. Thoroughly clean the seal O-ring groove in the front head. 2. Dip the new seal O-ring in clean 525 viscosity refrigerant oil. NOTE: Any attempt to use makeshift or inadequate service tools or equipment may result in damage and/or improper compressor operation. 3. Assemble the O-ring onto the J 33011. 4. Install the O-ring. 4.1. Insert the J 33011 into the compressor neck until the installer bottoms out. IMPORTANT: The top groove in the compressor neck is for the shaft seal retainer ring. 4.2. Lower the moveable slide of the J 33011 in order to release the O-ring into the seal O-ring lower grove. 4.3. Rotate the J 33011 in order to seat the O-ring. 4.4. Remove the installer. 5. Dip the new shaft seal in clean 525 viscosity refrigerant oil. 6. Assemble the seal to the J 23128-A by turning the handle clockwise. 6.1. Ensure that the stamped steel case side of the lip seal engages with the knurled tangs of the J 23128-A. 6.2. Ensure that the flared-out side of the lip seal faces toward the compressor. NOTE: Use care when handling the seal protector. Do not nick the seal protector. This may damage the seal during installation. Ensure that the bottom of the seal protector is not flared. This may damage the seal during installation. 7. Install the J 34614 on the lip seal. 8. Install the lip seal onto the shaft. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Compressor Shaft Seal Removal (V5 - Direct Mount) > Page 9732 8.1. Place the J 34614 over the end of the compressor shaft. 8.2. Slide the new seal onto the shaft using a rotary motion of the J 23128-A. 8.3. Ensure that the seal makes good contact with the O-ring. Do not dislodge the O-ring. 8.4. Disengage the J 23128-A from the seal. 8.5. Remove the J 23128-A and the J 34614 from the compressor. 9. Use the J 5403 in order to install the new seal retainer ring with the flat side against the seal. 10. Use the sleeve of the J 33011 in order to press in the seal retainer ring. Ensure that the ring snaps into the groove. 11. Leak test the compressor. Refer to Compressor Leak Testing (V5 Conventional Mount). 12. Remove any excess oil from the shaft and the inside of the compressor neck. 13. Install the clutch plate and hub assembly. 14. Install the compressor and the compressor belt. Tighten the bracket. 15. Evacuate and charge the refrigerant system using the J 39500-B. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Top Underhood Electrical Center Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 9736 Locations View Part of Underhood Accessory Wiring Junction Block (Top). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 9737 Compressor Clutch Relay: Description and Operation The compressor clutch coil is energized through the compressor control relay. This relay is activated by the PCM in A/C modes. The PCM provides cut-off of the relay under certain operating conditions, including wide open throttle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 9738 Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Release the retaining clip (1) and remove the engine wiring harness junction block (BOTTOM) cover (2). A/C Compressor Relay (A/C CMPR) (1) {In The Engine Wiring Harness Junction Block} 3. Remove the A/C compressor relay (A/C CMPR) (1) from the engine wiring harness junction block (BOTTOM). INSTALLATION PROCEDURE 1. Install the A/C compressor relay (A/C CM PR) (1) into the engine wiring harness junction block (BOTTOM). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 9739 2. Install the engine wiring harness junction block (BOTTOM) cover (2) and secure the retaining clip (1). 3. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Regrigerant (R-134A) Condenser HVAC: Specifications Regrigerant (R-134A) Regrigerant Capacity ........................................................................................................................... .......................................................... 1.0 kg (2.20 lb) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Regrigerant (R-134A) > Page 9744 Condenser HVAC: Specifications Oil, Polyalkylene Glycol (PAG) If the refrigerant oil was removed from the A/C system during the recovery process or during the component replacement, the refrigerant oil must be replenished. Add the refrigerant oil as indicated. A/C Compressor 60 ml (2oz) Condensor 30 ml (1 oz) Evaporator 90 ml (3 oz) Accumulator 30 ml (1 oz plus amount removed) Abrupt oil loss due to a large refrigerant leak Add 90 ml (3 oz) plus the required amount for the component being replaced 9 cause of the large leak. Refrigerant Oil type is Polyalkylene Glycol (PAG) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 9745 Condenser HVAC: Description and Operation The condenser is located in front of the radiator. The condenser is made up of aluminum tubing and aluminum cooling fins, which allows rapid heat transfer for the refrigerant. Compressed refrigerant enters the condenser in a high pressure, high temperature vapor state. As the refrigerant flows through the condenser, the heat of the refrigerant is transferred to the ambient air passing through the condenser. Cooling the refrigerant causes the refrigerant to condense and change from a vapor to a liquid. Refrigerant exiting the condenser is in a high-pressure, medium temperature liquid state. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 9746 Condenser HVAC: Service and Repair CONDENSER REPLACEMENT REMOVAL PROCEDURE 1. Remove the LH fender diagonal brace. 2. Remove the cross vehicle brace. 3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 4. Remove the radiator. 5. Remove the liquid line nut from the condenser and position the liquid line aside. 6. Remove the compressor line nut from the condenser and position the compressor line aside. 7. Remove the condenser. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 9747 INSTALLATION PROCEDURE 1. Install the condenser. IMPORTANT: Lubricate the new O-ring seals with mineral base 525 viscosity refrigerant oil. 2. Install the new O-ring seals onto the compressor hose and the liquid line. Refer to O-ring Replacement. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the liquid line to the condenser. Tighten Tighten the liquid line nut to 27 N.m (20 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 9748 4. Install the compressor hose to the condenser. Tighten Tighten the compressor hose nut to 16 N.m (12 lb ft). 5. Install the radiator. 6. Evacuate, charge the A/C system. Refer to Refrigerant Recovery and Recharging. See: Refrigerant/Service and Repair 7. Leak test the A/C system. Refer to Leak Testing. 8. Install the cross vehicle brace. 9. Install the LH fender diagonal brace. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > A/C - Control Knob Replacement Availability Control Assembly: Technical Service Bulletins A/C - Control Knob Replacement Availability Bulletin No.: 04-01-37-001 Date: January 06, 2004 INFORMATION Subject: HVAC Control Knob Replacement Models: 2000-2004 All Passenger Cars and Light Duty Trucks 2003-04 HUMMER H2 HVAC Control Knob Availability Important: If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. The various knobs used on the HVAC controls of most GM vehicles are available for purchase separately from the HVAC head units. If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. Please use only the labor operation code listed below when replacing an HVAC control knob. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 9753 Control Assembly: Specifications Control Assembly Bolts 1.8 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Component Locations Control Assembly: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Component Locations > Page 9756 Locations View Heater and A/C Control Center of the I/P. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Component Locations > Page 9757 Control Assembly: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Component Locations > Page 9758 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Blower Motor Control Module, C1 Blower Motor Control Module, C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Blower Motor Control Module, C1 > Page 9761 Heater - A/C Control Module, C2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Control Assembly (CJ3) Control Assembly: Description and Operation Control Assembly (CJ3) CJ3 Control Assembly Description (CJ3) The CJ3 system allows the driver and the passenger to maintain separate temperature settings. The system works best if you keep your windows closed while using it. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID See: Application and ID/RPO Codes Fan Control (1) The knob (1) on the left side of the climate control panel controls the fan speed. To turn the fan off, turn the knob to the OFF position. If the airflow seems very low when the fan is adjusted to the highest setting regardless of the mode setting, your passenger compartment air filter may need to be replaced. Driver's (D) Temperature Control (2) The lever (2) on the left adjusts the air temperature on the driver's side independent of the temperature set by the passenger. Slide the lever towards the red area (upward) to raise the temperature. Slide the lever towards the blue area (downward) to lower the temperature. Passenger's (P) Temperature Control (3) The lever (3) on the right adjusts the air temperature on the passenger's side independent of the temperature set by the driver. Slide the lever towards the red area (upward) to raise the temperature. Slide the lever towards the blue area (downward) to lower the temperature. Mode Control (4) The knob on the right side of the control panel has several settings to control the direction of airflow UPPER (5) This setting directs air through the instrument panel outlets. BI-LEVEL (6) This setting directs air four ways. Half of the air is directed through the instrument panel outlets. Most of the remaining air is directed through the floor ducts and a little to the windshield defroster and side window outlets. LOWER (7) This setting sends most of the air through the floor ducts. The remaining air comes out of the defroster and side window outlets. DEFOG (8) This setting sends half of the air to the floor ducts and half to the defroster and side window outlets. The air conditioning compressor will run automatically in this setting unless the outside temperature is below 4°C (40°F). Air inlet will also be automatically set to outside air. The RECIRCULATION (12) button will not be selectable in this mode. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Control Assembly (CJ3) > Page 9764 DEFROST (9) This setting directs most of the air through the defroster and side window vents. Some of the air also goes to the floor ducts. The air conditioning compressor will run automatically in this setting unless the outside temperature is below 4°C (40°F). The air inlet will also be automatically set to outside air. The RECIRCULATION (12) button will not be selectable in this mode. Rear Window Defogger (Rear) (10) Press the button (10) marked REAR to turn the defogger on. An indicator on the button will light. The rear window defogger uses a warming grid to remove fog from the rear window. The rear window defogger will turn itself off after about 15 minutes. If you turn it on again, the defogger will only run for about 7.5 minutes before turning off. You can also turn the defogger off by turning the ignition off or by pressing the button again. A/C (11) Press this button (11) to turn the air conditioning on and off. The system will cool and dehumidify the air inside the vehicle when the A/C light is on RECIRCULATION (12) Press this button (12) to limit the amount of fresh air entering your vehicle. This is helpful when you are tying to limit odors entering your vehicle. This button is usable in UPPER (5), LOWER (7) and BI-LEVEL (6) modes. An indictor on the button will light up when this button is selected. OUTSIDE AIR (13) Press this button (13) to force the system to use outside air. This button is usable in all of the air delivery modes on the mode knob (4). An indicator on the button will light up when this button is selected. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Control Assembly (CJ3) > Page 9765 Control Assembly: Description and Operation Control Assembly (C60) C60 Control Assembly Description (C60) With the C60 system, you can control the heating, cooling and ventilation in your vehicle. The system works best it you keep your windows closed while using it. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID See: Application and ID/RPO Codes Fan Control (1) The knob (1) on the left side of the control assembly controls the fan speed. To turn the fan off, turn the knob to the OFF position. If airflow seems very low when the fan knob is turned to the highest setting, regardless of the mode setting, your passenger compartment air filter (if equipped) may need to be replaced. Temperature Control (2) The center knob (2) on the control assembly changes the temperature of the air coming through the system. Turn this knob toward red area (clockwise) for warmer air. Turn it toward blue area (counterclockwise) for cooler air. Mode Control (3) The right knob (3) on the control assembly has several settings to control the direction of airflow. UPPER (4) This setting directs air through the instrument panel outlets. BI-LEVEL (5) This setting directs air four ways. Half of the air is directed through the instrument panel outlets. Most of the remaining air is directed through the floor ducts and a little to the windshield defroster and side window outlets. LOWER (6) This setting sends most of the air through the ducts near the floor. The remaining air comes out of the defroster and side window outlets. DEFOG (7) This setting sends half of the air to the floor ducts and half to the defroster and side window outlets. The air conditioning compressor will run automatically in this setting unless the outside temperature is below 4°C (40°F). Air inlet will also be automatically set to outside air. The RECIRCULATION button will not be selectable in this mode. DEFROST (8) This setting directs most of the air through the defroster and side window outlets. Some of the air also goes to the floor ducts. The air conditioning compressor will run automatically in this setting unless the outside temperature is below 4°C (40°F). The air inlet will also be automatically set to outside air. The RECIRCULATION button will not be selectable in this mode. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Control Assembly (CJ3) > Page 9766 Rear Window Defogger (Rear)(9) Press the button (9) marked REAR to turn the defogger on. An indicator on the button will light. The rear window defogger uses a warming grid to remove fog from the rear window. The rear window defogger will turn itself off after about 15 minutes. If you turn it on again, the defogger will only run for about 7.5 minutes before turning off. You can also turn the defogger off by turning the ignition off or by pressing the button again. A/C (10) Press this button (10) to turn the air conditioning on and off. The system will cool and dehumidify the air inside the vehicle when the A/C light is on RECIRCULATION (11) Press this button (11) to limit the amount of fresh air entering your vehicle. This is helpful when you are trying to limit odors entering your vehicle. This button is usable in UPPER, LOWER and BI-LEVEL modes. An indictor on the button will light up when this button is selected. OUTSIDE AIR (12) Press this button (12) to force the system to use outside air. This button is usable in all of the air delivery modes on the mode knob (3). An indicator on the button will light up when this button is selected. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Control Assembly Replacement (CJ3) Control Assembly: Service and Repair Control Assembly Replacement (CJ3) REMOVAL PROCEDURE 1. Remove the I/P trim plate. 2. Remove the front floor console if equipped. 3. Remove the retaining bolts from the HVAC control assembly. 4. Pull the control assembly out from the instrument panel. 5. Disconnect the electrical connectors (1) and the vacuum connectors (2) from the HVAC control assembly. 6. Remove the HVAC control assembly. INSTALLATION PROCEDURE 1. Connect the electrical connectors (1) and the vacuum harness (2) to the HVAC control assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Control Assembly Replacement (CJ3) > Page 9769 2. Install the HVAC control assembly into the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the retaining bolts to secure the HVAC control assembly. Tighten Tighten the control assembly bolts to 1.8 N.m (16 lb in). 4. Install the I/P trim plate. 5. Install the front floor console if equipped. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Control Assembly Replacement (CJ3) > Page 9770 Control Assembly: Service and Repair Control Assembly Replacement (C60) REMOVAL PROCEDURE 1. Remove the I/P trim plate. 2. Remove the front floor console if equipped. 3. Remove the retaining bolts from the HVAC control assembly. 4. Pull the control assembly out from the instrument panel. 5. Disconnect the electrical connectors (1) and the vacuum connectors (2) from the HVAC control assembly. 6. Remove the HVAC control assembly. INSTALLATION PROCEDURE 1. Connect the electrical connectors (1) and the vacuum connectors (2) to the HVAC control assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Control Assembly Replacement (CJ3) > Page 9771 2. Install the HVAC control assembly into the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the retaining bolts to secure the HVAC control assembly. Tighten Tighten the control assembly bolts to 1.8 N.m (16 lb in). 4. Install the I/P trim plate. 5. Install the front floor console if equipped. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Description and Operation A/C Coupler O-ring: Description and Operation Install new approved service replacement air conditioning O-ring(s) and flat washers whenever a joint or fitting is disassembled. Some vehicles use flat sealing washers and O-ring(s) to seal the refrigerant system. The flat washers are used on block fittings of refrigerant components. The O-ring(s) is used to seal the refrigerant tubes. The O-ring fitting consists of: ^ An aluminum alloy, externally threaded fitting which is welded to an aluminum tube. ^ A free-spinning internally threaded nut. ^ An aluminum tube end which accommodates the O-ring(s). Verify that the flat washers or O-ring(s) have not been damaged prior to installation. Replace damaged parts. Coat O-ring(s) and flat washers with the approved refrigerant oil. Failure to use the proper service replacement parts and procedures may result in a leak. Service Caps Seal The primary seal for the service ports is the sealing cap. The cap contains a specially designed O-ring or gasket which provides a leak free seal. Should the cap be loose, missing, or the wrong usage, a loss of refrigerant could result. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Description and Operation > Page 9776 A/C Coupler O-ring: Service and Repair REMOVAL PROCEDURE 1. Remove the cross vehicle brace. 2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 3. For compression-style fittings: use a back-up wrench on the A/C refrigerant component (smaller size) fitting (2), then loosen the A/C refrigerant hose (larger size) fitting (1). 4. For banjo-style fittings; remove the bolt/nut retaining the A/C refrigerant hose to the A/C refrigerant component. IMPORTANT: Cap or tape the open A/C refrigerant hose and the A/C refrigerant component immediately. 5. Disconnect the A/C refrigerant hose from the A/C refrigerant component, discard the O-ring seal and cap or tape the A/C refrigerant hose and the A/C refrigerant component to prevent contamination. INSTALLATION PROCEDURE 1. Remove the cap or tape from the A/C refrigerant hose and the A/C refrigerant component. 2. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant hose and the A/C refrigerant component. 3. For compression-style fittings; carefully slide the new O-ring seal (1) onto the A/C refrigerant hose until seated. IMPORTANT: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system. 4. Lightly lubricate the new O-ring seal (1) with mineral base 525 viscosity refrigerant oil. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Description and Operation > Page 9777 5. For banjo-style fittings: carefully slide the new O-ring seal (1) onto the A/C refrigerant hose until seated. IMPORTANT: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system. 6. Lightly lubricate the new O-ring seal (1) with mineral base 525 viscosity refrigerant oil. Leave a light coating of the refrigerant oil to remain on the A/C refrigerant hose in the area indicated (2) ONLY. 7. Install the A/C refrigerant hose to the A/C refrigerant component. 8. For compression-style fittings; use a back-up wrench on the A/C refrigerant component (smaller size) fitting (2), then tighten the A/C refrigerant hose (larger size) fitting (1) to specification. 9. For banjo-style fittings; install the bolt/nut retaining the A/C refrigerant hose to the A/C refrigerant component, then tighten to specification. 10. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging. See: Refrigerant/Service and Repair 11. Check the A/C refrigerant hose(s) to the A/C component(s) joints for leaks. Refer to Leak Testing. 12. Install the cross vehicle brace. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 00-01-38-012 > Dec > 00 > Evaporator Case - Water Leaks to The Interior Evaporator Case: Customer Interest Evaporator Case - Water Leaks to The Interior File In Section: 01 - HVAC Bulletin No.: 00-01-38-012 Date: December, 2000 TECHNICAL Subject: Carpet Wet On Passenger Side of Vehicle (Clean Evaporator Case Drain, If Plugged) Models: 1999-2000 Buick Century, Regal 1999-2000 Chevrolet Monte Carlo 2000 Chevrolet Impala 1999-2000 Oldsmobile Intrigue 1999-2000 Pontiac Grand Prix Condition Some customers may comment that the carpet on the front passenger side is wet. Cause This may be caused by foreign material plugging the evaporator case drain. Correction Inspect the evaporator case drain for plugging. 1. Raise the vehicle on a hoist. 2. Remove the rubber elbow from the evaporator case drain tube by pulling the elbow straight off. 3. Insert a 9 mm (11/32 in) drill bit, or any other similar-type instrument, into the evaporator case drain to clean out the material that is blocking the drain. (The distance to the other side of the evaporator case is 130 mm (5 in)). 4. Re-install the evaporator case drain rubber elbow. A small amount of silicone spray on the inside of the rubber tube will allow it to be slipped into place very easily. Be sure that the rubber elbow drain hole is open. If the evaporator case drain was not plugged, a water leak test will need to be performed using normal water testing procedures. If no external water leak was found and the vehicle returns for the same type concern, the evaporator case will have to be removed from the vehicle and the foreign material removed from the evaporator case. Parts Information No parts are required to perform this procedure. If the rubber elbow is missing from the vehicle, install a new elbow. The addition of this rubber elbow will result in road and wind noise reduction at highway speeds. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 00-01-38-012 > Dec > 00 > Evaporator Case Water Leaks to The Interior Evaporator Case: All Technical Service Bulletins Evaporator Case - Water Leaks to The Interior File In Section: 01 - HVAC Bulletin No.: 00-01-38-012 Date: December, 2000 TECHNICAL Subject: Carpet Wet On Passenger Side of Vehicle (Clean Evaporator Case Drain, If Plugged) Models: 1999-2000 Buick Century, Regal 1999-2000 Chevrolet Monte Carlo 2000 Chevrolet Impala 1999-2000 Oldsmobile Intrigue 1999-2000 Pontiac Grand Prix Condition Some customers may comment that the carpet on the front passenger side is wet. Cause This may be caused by foreign material plugging the evaporator case drain. Correction Inspect the evaporator case drain for plugging. 1. Raise the vehicle on a hoist. 2. Remove the rubber elbow from the evaporator case drain tube by pulling the elbow straight off. 3. Insert a 9 mm (11/32 in) drill bit, or any other similar-type instrument, into the evaporator case drain to clean out the material that is blocking the drain. (The distance to the other side of the evaporator case is 130 mm (5 in)). 4. Re-install the evaporator case drain rubber elbow. A small amount of silicone spray on the inside of the rubber tube will allow it to be slipped into place very easily. Be sure that the rubber elbow drain hole is open. If the evaporator case drain was not plugged, a water leak test will need to be performed using normal water testing procedures. If no external water leak was found and the vehicle returns for the same type concern, the evaporator case will have to be removed from the vehicle and the foreign material removed from the evaporator case. Parts Information No parts are required to perform this procedure. If the rubber elbow is missing from the vehicle, install a new elbow. The addition of this rubber elbow will result in road and wind noise reduction at highway speeds. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 9799 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 9800 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 9806 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 9807 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Mechanical Specifications Evaporator Core: Mechanical Specifications Evaporator Core Block Fitting Bolt 16 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Mechanical Specifications > Page 9810 Evaporator Core: Capacity Specifications If the refrigerant oil was removed from the A/C system during the recovery process or during the component replacement, the refrigerant oil must be replenished. Add the refrigerant oil as indicated. A/C Compressor 60 ml (2oz) Condensor 30 ml (1 oz) Evaporator 90 ml (3 oz) Accumulator 30 ml (1 oz plus amount removed) Abrupt oil loss due to a large refrigerant leak Add 90 ml (3 oz) plus the required amount for the component being replaced 9 cause of the large leak. Refrigerant Oil type is Polyalkylene Glycol (PAG) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 9811 Evaporator Core: Description and Operation The evaporator cools and dehumidifies air before the air enters the passenger compartment. The following events occur in the evaporator: 1. Low-pressure, low temperature liquid/vapor refrigerant enters the evaporator. 2. The refrigerant flows through the evaporator's tubing. 3. The refrigerant evaporates. 4. The refrigerant exits the evaporator as low-pressure, low temperature, mostly vapor refrigerant. 5. As the refrigerant evaporates, the refrigerant absorbs heat from the air flowing over the evaporator. As the process of heat loss from the air to the evaporator core is taking place, any moisture (humidity) in the air condenses on the outside surface of the evaporator core and the moisture drains off as water. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 9812 Evaporator Core: Service and Repair EVAPORATOR CORE REPLACEMENT REMOVAL PROCEDURE 1. Remove the HVAC module, Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/ See: Housing Assembly HVAC/Service and Repair 2. Remove all of the outer HVAC module seals. 3. Remove the air inlet housing. 4. Unclip the heater/defrost valve vacuum actuator from the HVAC module. Remove the heater/defrost valve vacuum actuator. 5. Remove the HVAC module case upper screws. 6. Separate the HVAC module case (1). 7. Remove the HVAC module seal (2) from the lower case (1). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 9813 8. Remove the evaporator core. 9. Remove and discard the evaporator core lower seals. 10. Remove and discard the evaporator core upper seal. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 9814 11. Remove and discard the evaporator core side seal. 12. Remove and discard the water core filter. INSTALLATION PROCEDURE 1. Install the new water core filter to the evaporator core. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 9815 2. Install a new side seal to the evaporator core. 3. Install a new upper seal to the evaporator core. 4. Install two new lower seals to the evaporator core. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 9816 5. Install the new HVAC module seal (2) to the lower module case (1). 6. Install the evaporator core into the HVAC module lower case. 7. Align retaining clip (1) and install the upper and lower HVAC mode case. NOTE: Refer to Fastener Notice in Service Precautions. 8. Install the HVAC module case upper screws. Tighten Tighten the HVAC module case screws to 1.5 N.m (13 lb in). 9. Install the clip heater/defrost valve vacuum actuator to the HVAC module. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 9817 10. Install the air inlet housing. Tighten Tighten the air inlet housing screws to 1.5 N.m (13 lb in). 11. Install the HVAC module, Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/ See: Housing Assembly HVAC/Service and Repair Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest: > 00-01-38-012 > Dec > 00 > Evaporator Case - Water Leaks to The Interior Evaporator Drain Tube: Customer Interest Evaporator Case - Water Leaks to The Interior File In Section: 01 - HVAC Bulletin No.: 00-01-38-012 Date: December, 2000 TECHNICAL Subject: Carpet Wet On Passenger Side of Vehicle (Clean Evaporator Case Drain, If Plugged) Models: 1999-2000 Buick Century, Regal 1999-2000 Chevrolet Monte Carlo 2000 Chevrolet Impala 1999-2000 Oldsmobile Intrigue 1999-2000 Pontiac Grand Prix Condition Some customers may comment that the carpet on the front passenger side is wet. Cause This may be caused by foreign material plugging the evaporator case drain. Correction Inspect the evaporator case drain for plugging. 1. Raise the vehicle on a hoist. 2. Remove the rubber elbow from the evaporator case drain tube by pulling the elbow straight off. 3. Insert a 9 mm (11/32 in) drill bit, or any other similar-type instrument, into the evaporator case drain to clean out the material that is blocking the drain. (The distance to the other side of the evaporator case is 130 mm (5 in)). 4. Re-install the evaporator case drain rubber elbow. A small amount of silicone spray on the inside of the rubber tube will allow it to be slipped into place very easily. Be sure that the rubber elbow drain hole is open. If the evaporator case drain was not plugged, a water leak test will need to be performed using normal water testing procedures. If no external water leak was found and the vehicle returns for the same type concern, the evaporator case will have to be removed from the vehicle and the foreign material removed from the evaporator case. Parts Information No parts are required to perform this procedure. If the rubber elbow is missing from the vehicle, install a new elbow. The addition of this rubber elbow will result in road and wind noise reduction at highway speeds. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-01-38-012 > Dec > 00 > Evaporator Case - Water Leaks to The Interior Evaporator Drain Tube: All Technical Service Bulletins Evaporator Case - Water Leaks to The Interior File In Section: 01 - HVAC Bulletin No.: 00-01-38-012 Date: December, 2000 TECHNICAL Subject: Carpet Wet On Passenger Side of Vehicle (Clean Evaporator Case Drain, If Plugged) Models: 1999-2000 Buick Century, Regal 1999-2000 Chevrolet Monte Carlo 2000 Chevrolet Impala 1999-2000 Oldsmobile Intrigue 1999-2000 Pontiac Grand Prix Condition Some customers may comment that the carpet on the front passenger side is wet. Cause This may be caused by foreign material plugging the evaporator case drain. Correction Inspect the evaporator case drain for plugging. 1. Raise the vehicle on a hoist. 2. Remove the rubber elbow from the evaporator case drain tube by pulling the elbow straight off. 3. Insert a 9 mm (11/32 in) drill bit, or any other similar-type instrument, into the evaporator case drain to clean out the material that is blocking the drain. (The distance to the other side of the evaporator case is 130 mm (5 in)). 4. Re-install the evaporator case drain rubber elbow. A small amount of silicone spray on the inside of the rubber tube will allow it to be slipped into place very easily. Be sure that the rubber elbow drain hole is open. If the evaporator case drain was not plugged, a water leak test will need to be performed using normal water testing procedures. If no external water leak was found and the vehicle returns for the same type concern, the evaporator case will have to be removed from the vehicle and the foreign material removed from the evaporator case. Parts Information No parts are required to perform this procedure. If the rubber elbow is missing from the vehicle, install a new elbow. The addition of this rubber elbow will result in road and wind noise reduction at highway speeds. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Drain Tube: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Drain Tube: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9836 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Drain Tube: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9837 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Drain Tube: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9838 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Drain Tube: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9844 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Drain Tube: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9845 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Drain Tube: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9846 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations Expansion Block/Orifice Tube: Locations The plastic expansion tube, is located between the condenser outlet and the evaporator inlet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 9850 Expansion Block/Orifice Tube: Description and Operation Expansion (Orifice) Tube Description The plastic expansion tube, is located between the condenser outlet and the evaporator inlet. The expansion tube includes a mesh screen and an orifice. The tube restricts the high pressure liquid refrigerant in the liquid line. The system meters the flow of refrigerant to the evaporator as a low-pressure liquid. The filter screens on both the inlet (1) and the outlet (3) sides protect the expansion tube and the orifice form contamination. When the system diagnostics indicate a restricted expansion tube, it may not be necessary to replace the tube. Metal chips, flakes or slivers found on the screen may be removed with compressed air. The expansion tube is reusable if the none following conditions are present: ^ A broken plastic frame ^ A damaged or plugged brass expansion tube ^ Any torn screen material ^ A plugged screen (gritty material in screen) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 9851 Expansion Block/Orifice Tube: Service and Repair EXPANSION (ORIFICE) TUBE REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner and duct assembly. 2. Remove the cross vehicle brace. 3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 4. Remove the vacuum brake booster. 5. Remove the condenser tube. 6. Remove the expansion (orifice) tube: 6.1. Use needle-nose pliers in order to grip the orifice tube. 6.2. Use a turning motion along with a push-pull motion in order to loosen the impacted orifice tube. 6.3. Remove the orifice tube. IMPORTANT: DO NOT use any solvents or chemicals to clean the expansion (orifice) tube porous plastic inlet filter. 7. Inspect the expansion (orifice) tube for the following conditions and clean or replace with a new tube as indicated: ^ Broken plastic frame (1); replace tube. ^ Inlet filter (3) damaged or plugged with fine gritty material; replace tube. ^ Inlet filter (3) coated with metal chips, flakes, or slivers; coating may be removed with low pressure shop air ONLY and reused if cleaned satisfactorily. ^ If reusing the tube, discard the O-ring seals (2). INSTALLATION PROCEDURE IMPORTANT: Lubricate the new O-ring seals (2) with mineral base 525 viscosity refrigerant oil. 1. Install the new O-ring seals (2), if reusing the orifice tube. 2. CAREFULLY grasp the edge of the expansion (orifice) tube (1) without touching the inlet filter (porous plastic) (3) and insert into the condenser tube until fully seated. 3. Install the condenser tube. 4. Install the vacuum brake booster. 5. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. See: Refrigerant/Service and Repair 6. Inspect the A/C system for leaks. Refer to Leak Testing. 7. Install the cross vehicle brace. 8. Install the air cleaner and duct assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 9856 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 9857 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9858 Heater Core: Specifications Heater Core Line Clamp Screw 1.5 Nm Heater Core Mounting Clip Screw 1.5 Nm Heater Core Cover Screws 1.5 Nm Heater Core Outlet Cover Screws 1.5 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9859 Heater Core: Description and Operation The heater core is the main component of the heater system. The heater core is located inside of the heater and evaporator module. Engine coolant is pumped into the heater core from the engine whenever the engine is operating. The heater core fins transfers the heat from the engine coolant to the air passing over the heater core. The heater core has specific inlet and outlet tubes. The placement of the heater hoses should be noted prior to servicing the heater core or the heater hoses. The temperature control is linked to the temperature valve by a flexible control cable. When you rotate temperature control counterclockwise to the full COLD position, the temperature valve is held snugly against the air entrance to the heater core. The following actions occur: ^ All of the airflow from the evaporator bypasses the heater core. ^ No heat transfer occurs. When you turn the temperature control away from the full COLD position, the temperature valve begins to direct air to the heater core. This action allows air to flow through the heater core. The farther the temperature control is rotated clockwise, the more the temperature valve directs air through the heater core. The air discharge is warmer when most of the airflow is heated in this manner. The air discharge is warmer because the heated and unheated air flows join and mix together thoroughly beyond the heater core. When you rotate the temperature lever clockwise to the full HOT position, the temperature valve blocks off the passage that allows air to bypass the heater core. This action causes passage of the airflow through the heater core. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9860 Heater Core: Service and Repair HEATER CORE REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner and duct assembly. 2. Remove the fuel injector sight shield if equipped with 3.8L. 3. Drain the coolant. Refer to Draining and Filling Cooling System in Engine Cooling. 4. Disconnect the heater hoses at the heater core. 5. Remove the LH and RH instrument panel insulators. 6. Remove the lower the floor console, if equipped. 7. Remove the bolts and position the HVAC wiring harness bracket aside. IMPORTANT: Position the heater outlet cover downward and rearward in order to disconnect the cover from the rear area floor duct assembly. 8. Remove the heater outlet cover screws. 9. Remove the heater outlet cover. 10. Remove the heater core cover screws. 11. Remove the heater core cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9861 12. Remove and discard the seals (1,2,3) from the heater core cover. 13. Remove and discard the heater core outer seal (5) from the heater core. 14. Remove the heater core pipe retainer clamp screw (2). 15. Remove the heater core line clamp screw (1). 16. Remove the heater core retaining clamp. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9862 17. Remove the heater core from the HVAC lower case. 18. Remove the heater core tube support bracket (clamp). 19. Remove and discard the heater core lower seal (4) from the HVAC case. 20. Remove and discard the heater core center seal (3) from the HVAC case. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9863 21. Remove and discard the heater core upper seal (2) from the HVAC lower case. 22. Remove and discard the heater core side seals (1) from the HVAC lower case. INSTALLATION PROCEDURE 1. Install the heater core side seals (1) to the HVAC lower case. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9864 2. Install the heater core upper seal (2) to the HVAC lower case. 3. Install the heater core center seal (3) to the HVAC case. 4. Install the heater core lower seal (4) to the HVAC case. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9865 5. Install the heater core tube support bracket (clamp). 6. Install the heater core from the HVAC lower case. NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the heater core line clamp screw (2). Tighten Tighten the heater core line clamp screw to 1.5 N.m (13 lb in). 8. Install the heater core mounting clip with a screw (1). Tighten Tighten the heater core mounting clip screw to 1.5 N.m (13 lb in) 9. Install heater core outer seal (5) to the heater core. 10. Install new seals (1,2,3) to the heater core cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9866 11. Install the heater core cover. 12. Install the heater core cover screws. Tighten Tighten the heater core cover screws to 1.5 N.m (13 lb in). 13. Install the heater core outlet cover. 14. Install the heater core outlet cover screws. Tighten Tighten the heater core outlet cover screws to 1.5 N.m (13 lb in). 15. Install the HVAC wiring harness bracket. Install the HVAC wiring harness bracket bolts. Tighten Tighten the HVAC wiring harness bracket bolts to 10 N.m (89 lb in). 16. Install the lower the floor console, if equipped. 17. Install the LH and RH instrument panel insulators. 18. Connect the heater hoses at the heater core. 19. Refill the coolant. Refer to Draining and Filling Cooling System in Engine Cooling. 20. Install the fuel injector sight shield if equipped with 3.8L. 21. Install the air cleaner and duct assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Specifications Heater Hose: Specifications Heater Inlet Pipe Nut 7 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Handling of Refrigerant Lines and Fittings Heater Hose: Service and Repair Handling of Refrigerant Lines and Fittings ^ Ensure that the metal lines do not exhibit the following conditions. This will prevent the loss of system capacity due to line restriction: Dents - kinks ^ Do not bend the flexible hose line to a radius of less that 4 times the diameter of the hose. ^ Do not allow the flexible hose line to come within a distance of 63.5 mm (2 1/2 in) of the exhaust manifold. ^ Inspect the flexible hose lines regularly. Replace the flexible hose line with new hose if one of the following conditions exist: Leaks - Brittleness - Deterioration ^ Before disconnecting any fitting in the refrigeration system, discharge all of the Refrigerant-134a. ^ Once you open a refrigerant line to the atmosphere, cap or tape the line immediately. This will prevent any of the following items from entering the line: Moisture - Dirt ^ Use the proper wrenches when you make connections on the O-ring fittings. Back-up the opposing fitting with a wrench in order to prevent distortion of the following areas: The connecting lines - The components ^ Tighten all of the tubing connections to the specified torque. ^ Too much or too little torque may result in the following conditions: Loose joints - Deformed joint parts - Refrigerant leakage - An inoperative A/C system ^ Ensure that the O-rings and the seats are in perfect condition. A burr or a piece of dirt may cause a refrigerant leak. ^ Install new O-rings that you have lubricated with the mineral base 525 viscosity refrigerant oil. Do not use Polyalkylene Glycol (PAG) synthetic oil. Do not wipe the threads with a cloth. ^ Keep PAG synthetic refrigerant oil off fitting threads. Long term contact of PAG synthetic oil on threads may cause future disassembly difficulties. Flush threads of fitting with mineral base 525 viscosity refrigerant oil. Do not use PAG synthetic oil. Do not wipe threads with a cloth. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Handling of Refrigerant Lines and Fittings > Page 9872 Heater Hose: Service and Repair Heater Hoses Replacement REMOVAL PROCEDURE Tools Required J 38185 Hose Clamp Pliers 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling. 2. Use J 38185 in order to position aside the heater hose inlet and/or outlet clamp. 3. Disconnect the heater inlet hose and/or the outlet hose from the inlet and/or outlet pipe. 4. Use J 38185 in order to position aside the heater core inlet and/or outlet hose clamp. 5. Disconnect the heater inlet hose and/or the outlet hose from the heater core. 6. Remove the heater inlet hose and/or the outlet hose. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Handling of Refrigerant Lines and Fittings > Page 9873 1. Install the heater inlet hose and/or outlet hose. 2. Connect the heater inlet hose and/or the outlet hose to the heater core. IMPORTANT: Position heater core hose clamps in the indicated location. 3. Use J 38185 in order to secure the heater core hose inlet and/or outlet clamp. 4. Connect the heater inlet hose and/or the outlet hose to the inlet and/or outlet pipe. 5. Use J 38185 in order to secure the heater hose inlet and/or outlet clamp. 6. Refill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Handling of Refrigerant Lines and Fittings > Page 9874 Heater Hose: Service and Repair Heater Pipe Replacement - Inlet TOOLS REQUIRED J 38185 Hose Clamp Pliers 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling. 2. Remove the air cleaner and duct assembly. 3. Disconnect the inlet hose (3) from the inlet pipe. 4. Use J 38185 in order to position aside the heater hose inlet clamp. 5. Remove the inlet pipe mounting nut. 6. Remove the inlet pipe. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Handling of Refrigerant Lines and Fittings > Page 9875 1. Install the inlet pipe. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the inlet pipe mounting nut. Tighten Tighten the heater inlet pipe nut to 7 N.m (62 lb in). 3. Connect the inlet hose (3) to the inlet pipe. 4. Use J 38185 in order to position the heater hose inlet clamp. 5. Install the air cleaner and duct assembly. 6. Refill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > Heating, Ventilation and Air Conditioning High Pressure Safety Valve HVAC: Description and Operation Heating, Ventilation and Air Conditioning HIGH PRESSURE RELIEF VALVE DESCRIPTION The compressor is equipped with a pressure relief valve which is placed in the system as a safety factor. Under certain conditions, the refrigerant on the discharge side may exceed the designed operating pressure. To prevent system damage, the valve is designed to open automatically at approximately 3036 kPa (455 to 525 psi). Correct any condition that causes this valve to open and replace any expelled refrigerant oil. Inspect the air conditioning refrigerant pressure sensor for proper calibration. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > Heating, Ventilation and Air Conditioning > Page 9880 High Pressure Safety Valve HVAC: Description and Operation HVAC System - Manual The compressor is equipped with a pressure relief valve which is placed in the system as a safety factor. Under certain conditions, the refrigerant on the discharge side may exceed the designed operating pressure. To prevent system damage, the valve is designed to open automatically at approximately 3036 kPa (455 to 525 psi). Correct any condition that causes this valve to open and replace any expelled refrigerant oil. Inspect the air conditioning refrigerant pressure sensor for proper calibration. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > V5 - Conventional Mount High Pressure Safety Valve HVAC: Service and Repair V5 - Conventional Mount Compressor Pressure Relief Valve Removal TOOLS REQUIRED J 41790 Compressor Holding Fixture 1. Install the compressor into the J 41790. 2. Remove the pressure relief valve (2) from the rear head of the compressor. Compressor Pressure Relief Valve Install 1. Clean the valve seat area on the rear head. 2. Lubricate the O-ring of the new pressure relief valve and the O-ring assembly using new 525 viscosity refrigerant oil. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the new pressure relief valve (2). Tighten Tighten the valve to 9 N.m (80 lb in). 4. Evacuate and recharge the system. 5. Perform a leak test. Refer to Compressor Leak Testing (V5 - Conventional Mount). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > V5 - Conventional Mount > Page 9883 High Pressure Safety Valve HVAC: Service and Repair V5 - Direct Mount Compressor Pressure Relief Valve Removal TOOLS REQUIRED J 41790 Compressor Holding Fixture 1. Install the compressor onto the J 41790. 2. Remove the pressure relief valve from the rear head of the compressor. Compressor Pressure Relief Valve Install TOOL REQUIRED J41790 Compressor Holding Fixture 1. Clean the pressure relief valve seat area of the rear head. 2. Lubricate the O-ring of the new pressure relief valve with clean 525 viscosity refrigerant oil. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the new pressure relief valve into the compressor. Tighten Tighten the pressure relief valve to 9 N.m (80 lb in). 4. Remove the compressor from the J 41790. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications Compressor Hose to Accumulator Nut 16 Nm Compressor Hose to Compressor Nut/Bolt 33 Nm Compressor Hose to Condenser Nut 16 Nm Suction Hose at Block Fitting Bolt 16 Nm Suction Hose Nut at Accumulator 47 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement Hose/Line HVAC: Service and Repair Compressor Hose Assembly Replacement REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the air cleaner and duct assembly. 3. Remove the cross vehicle brace. 4. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 5. Remove the compressor hose nut from the condenser and position the compressor hose aside. 6. Remove the compressor hose nut from the accumulator and position the compressor hose aside. 7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 8. Remove the lower air deflector. IMPORTANT: Remove and discard all the used O-rings and sealing washers. 9. Remove the compressor line at the compressor. 10. Remove the compressor hose assembly. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 9889 1. Install the compressor hose assembly. IMPORTANT: Lubricate the new O-rings with mineral base 525 viscosity refrigerant oil. 2. Install the new O-rings onto the compressor hose assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the compressor hose assembly at the rear of the compressor. Tighten Tighten the compressor hose bolt to 33 N.m (24 lb ft). 4. Install the compressor hose to the accumulator. 5. Install the compressor hose nut onto the accumulator. Tighten Tighten the compressor hose nut to 16 N.m (12 lb ft). 6. Install the compressor hose to the condenser. 7. Install the compressor hose nut. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 9890 Tighten Tighten the compressor hose nut to 16 N.m (12 lb ft). 8. Install the lower air deflector. 9. Lower the vehicle. 10. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. See: Refrigerant/Service and Repair 11. Inspect the system for leaks. Refer to Leak Testing. 12. Install the cross vehicle brace. 13. Install the air cleaner and duct assembly. 14. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 9891 Hose/Line HVAC: Service and Repair Condenser Tube Replacement REMOVAL PROCEDURE 1. Remove the air cleaner and duct assembly. 2. Remove the cross vehicle brace. 3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 4. Remove the vacuum brake booster. 5. Remove the liquid line from the bracket. 6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 7. Remove the lower air deflector. 8. Disconnect the electrical connector (2) from the A/C refrigerant pressure sensor (1). 9. Remove the liquid line nut at the condenser. 10. Lower the vehicle. 11. Remove the liquid line nut at the orifice. 12. Disconnect the transmission shift cable retainer from the strut tower and position aside the transmission shift cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 9892 IMPORTANT: Use care when removing the tube. 13. Remove the liquid line. 14. Remove and discard the O-rings. INSTALLATION PROCEDURE IMPORTANT: The new O-ring seals must be lubricated with mineral base 525 viscosity refrigerant oil. 1. Install new O-ring seals onto the liquid line. 2. Install the liquid line into place. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the liquid line nut at the orifice. Tighten Tighten the liquid line nut to 27 N.m (20 lb ft). 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 5. Install the liquid line nut at the condenser. Tighten Tighten the liquid line nut to 27 N.m (20 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 9893 6. Connect the electrical connector (2) to the A/C refrigerant pressure sensor (1). 7. Install the lower air deflector. 8. Lower the vehicle. 9. Install the liquid line into the bracket. 10. Install the vacuum brake booster. 11. Evacuate and charge the system. Refer to Refrigerant Recovery and Recharging. See: Refrigerant/Service and Repair 12. Inspect the system for leaks. 13. Install the cross vehicle brace. 14. Install the air cleaner and duct assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 9894 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement REMOVAL PROCEDURE 1. Remove the air cleaner and duct assembly. 2. Remove the cross vehicle brace. 3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 4. Remove the liquid/suction line bracket. 5. Remove the vacuum brake booster. 6. Remove the liquid line nut at the orifice. 7. Remove the liquid line at the block fitting. IMPORTANT: Use care when removing the liquid line. 8. Remove the liquid line. 9. Remove and discard the O-rings. INSTALLATION PROCEDURE IMPORTANT: The new O-ring seals must be lubricated with mineral base 525 viscosity refrigerant oil. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 9895 1. Install the new O-ring seals onto the liquid line. Refer to O-ring Replacement. 2. Install the liquid line into place. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the liquid line at the block fitting. Tighten Tighten the liquid line block fitting bolt to 16 N.m (12 lb ft). 4. Install the liquid line nut at the orifice. Tighten Tighten the liquid line nut to 27 N.m (20 lb ft). 5. Install the liquid line/suction line bracket. 6. Install the vacuum brake booster. 7. Evacuate and charge the system. Refer to Refrigerant Recovery and Recharging. See: Refrigerant/Service and Repair 8. Inspect the system for leaks. Refer to Leak Testing. 9. Install the cross vehicle brace. 10. Install the air cleaner and duct assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 9896 Hose/Line HVAC: Service and Repair Suction Hose Replacement REMOVAL PROCEDURE 1. Remove the air cleaner and duct assembly. 2. Remove the cross vehicle brace. 3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 4. Remove the brake modulator bracket. 5. Remove the liquid/suction line bracket. 6. Remove the suction line nut at the accumulator and position aside the suction line. 7. Remove the suction line block fitting bolt. IMPORTANT: Use care when removing the suction line. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 9897 8. Remove the suction line. 9. Remove and discard the suction line O-rings seals. INSTALLATION PROCEDURE IMPORTANT: The new O-ring seals must be lubricated with mineral base 525 viscosity refrigerant oil. 1. Install the new O-ring seals onto the suction line. 2. Install the suction line into place. 3. Install the suction line into the block fitting. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the suction line block fitting bolt. Tighten Tighten the suction line block fitting bolt to 16 N.m (12 lb ft). 5. Install the suction line to the accumulator. Tighten Tighten the suction line nut to 47 N.m (35 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 9898 6. Install the liquid/suction line bracket. 7. Install the brake modulator bracket. 8. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. See: Refrigerant/Service and Repair 9. Inspect the A/C system for leaks. Refer to Leak Testing. 10. Install the cross vehicle brace. 11. Install the air cleaner and duct assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Specifications Housing Assembly HVAC: Specifications HVAC Module to Dash Bolts/Nuts 10 Nm HVAC Module Upper Case Screws 1.5 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Specifications > Page 9902 Housing Assembly HVAC: Service and Repair HVAC MODULE ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the LH fender diagonal brace. 2. Remove the cross vehicle brace. 3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 4. Drain the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling. 5. Disconnect the A/C lines at the evaporator block fitting. 6. Disconnect the heater hoses at the heater core. 7. Remove the cross vehicle beam. 8. Disconnect the vacuum hoses from the HVAC module. 9. Disconnect the electrical connectors from the HVAC module. 10. Disconnect the IP wiring harness from the HVAC module retainers and position the IP wiring harness to the floor. 11. Remove the evaporator drain elbow. 12. Remove the HVAC module to dash nuts. 13. Perform the following steps to remove the HVAC module. 13.1. Pull the HVAC module rearward to disengage the mounting studs from the dash panel. 13.2. Position aside the dash insulator pad from the HVAC module air inlet opening. 13.3. Roll the HVAC module downward and rearward to disconnect the heater core outlet cover from the rear floor air outlet duct. 13.4. Remove the HVAC module. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Specifications > Page 9903 14. Remove and discard all of the outer HVAC module seals (1,2,3). INSTALLATION PROCEDURE 1. Install new outer HVAC module seals (1,2,3). IMPORTANT: When installing the HVAC module, ensure dash insulator pad cut-outs and HVAC seals, studs, and drain align and seal properly to dash panel. 2. Perform the following steps to install the HVAC module into the vehicle. 2.1. Align the HVAC module heater core outlet cover to the rear floor air outlet duct. 2.2. Roll the HVAC module forward and upward and align the dash insulator pad to the HVAC module air inlet opening. 2.3. Align the HVAC module mounting studs and drain to seat against the dash panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the HVAC module to dash nuts. Tighten Tighten the HVAC module nuts to 10 N.m (89 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Specifications > Page 9904 4. Install the evaporator drain elbow. 5. Position the IP wiring harness to the HVAC module and secure in the harness retainers. 6. Connect the electrical connectors to the HVAC module. 7. Connect the vacuum hoses to the HVAC module. 8. Install the cross vehicle beam. 9. Connect the heater hoses at the heater core. 10. Install the A/C lines at the evaporator block fitting. 11. Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling. 12. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 13. Leak test the A/C system. Refer to Leak Testing. 14. Install the cross vehicle brace. 15. Install the LH fender diagonal brace. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 9909 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 9910 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 9911 Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recharge Equipment File In Section: 01 - HVAC Bulletin No.: 99-01-38-006A Date: May, 2000 WARRANTY ADMINISTRATION Subject: J-43600 ACR 2000 Essential Refrigerant Recovery/Recharge Equipment Models: 1993-2000 Passenger Cars and Light Duty Trucks with R-134a Refrigerant This bulletin is being revised to change the effective date and to update the text. Please discard Corporate Bulletin Number 99-01-38-006 (Section 01 - HVAC). Effective June 1, 2000, the use of J-43600 ACR 2000 will be required on all repairs that require A/C system recovery and are reimbursable by GM. Additionally, GM highly recommends that J-43600 ACR 2000 be used on all GM cars and trucks for customer paid A/C repairs. Important: Also effective June 1, 2000, the "Add" time for all air conditioning recovery is revised to 0.5 hours for front systems and 0.7 hours for front/rear dual systems (RPO C69 or C34). After June 1, 2000, all air conditioning claims submitted with the 0.9 hours "Add" time will be rejected for "labor hours excessive". After the completion of repairs (charging), the ACR 2000 will prompt the user to perform a snapshot of the air conditioning system operating data. The snapshot includes: ^ Maximum high side pressure. ^ Minimum low side pressure. ^ Duct outlet temperatures (2). ^ Refrigerant purity information. This information is captured on a paper printout and in a warranty code. For all GM paid repairs, the paper printout should be attached to the shop copy of the repair order. The warranty code must be submitted in the warranty claim information in the comments field. The code enables the reporting of valuable information about the repair to GM for product quality improvement. Claims submitted without this information may be subject to review and subsequent debit. The required use of J-43600 ACR 2000 raises the question of the acceptable uses for any existing recovery/recycle equipment that GM dealers are currently using. GM recognizes that many of the previously essential ACR4's are reaching the end of their useful life. There are several alternatives for existing equipment that may be considered: ^ Use the existing equipment as customer paid recovery only equipment. Example: Collision repair area. ^ Use the existing equipment as a scavenger unit for contaminated A/C systems. ^ Sell the existing units to repair facilities outside the GM dealer network. ^ Discontinue the use of the existing units if the repair/maintenance costs exceed the value of the equipment. ^ Donate the existing equipment to local technical schools. ^ Dedicate the ACR4 to A/C system flushing, using the J-42939 Flush Adapter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 9912 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity ............................................................................................................................ ......................................................................... 1.0 kg Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 9915 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ..................................................................... R-134a Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 9916 Refrigerant: Description and Operation CAUTION: Refer to Breathing R-134a Caution in Service Precautions. Refrigerant performs the following functions in the air conditioning system: ^ Absorbs heat ^ Carries heat ^ Releases heat These vehicles use Refrigerant-134a (R-134a). Refrigerant-134a is a nontoxic, nonflammable, clear, colorless liquefied gas. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 9917 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED ^ J 39500-B A/C Refrigerant Recovery, Recycling and Recharging (ACR4) System ^ J 41810 Pure Guard 2 ^ J 41810-100A Active Flow Control Valve CAUTION: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: ^ R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. ^ To avoid system damage use only R-134a dedicated tools when servicing the A/C system. ^ Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. ^ R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 39500-B removes the Refrigerant - 134a from the vehicle's A/C system. The recovery procedure uses one filtering cycle. The evacuation procedure uses an automatic multiple pass filtering cycle. These filtering cycles ensure a constant supply of clean, dry refrigerant for the A/C system charging. The Initial Set-Up Instruction Manual, provided with the J 39500-B For ACR4 technical assistance in the U.S., call 1-800-345-2233. Refrigerant System Capacity For the amount of Refrigerant - 134a needed for A/C system (recharging). Refer to System Capacities. Refrigerant System Oil Charge Replenishing If refrigerant oil was removed from the A/C system during the recovery process, add the same amount of refrigerant oil to the system in the recharging process. The refrigerant oil must be replenished if the oil loss is due to component replacement or abrupt loss. Refer to Refrigerant Oil Distribution Specifications. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications System Capacity Polyalkaline Glycol (PAG) Refrigerant Oil System Capacity................................................................................................................................... ............................................... 8.45 fl. oz. (250 ml) Refrigerant Oil Distribution Specifications If the refrigerant oil was removed from the A/C system during the recovery process or during the component replacement, the refrigerant oil must be replenished. Add the refrigerant oil as indicated. Accumulator ......................................................................................................................................... .......................................................................... 30 ml Compressor .................................................... .............................................................................................................................................................. .. 60 ml Condenser .............................................................................................................................. ........................................................................................ 30 ml Evaporator ........................................ .............................................................................................................................................................. ................ 90 ml Abrupt Loss ............................................................................................................... ..................................................................................................... 90 ml NOTE: Replacement compressors do not have any oil in the compressor. Add the correct amount of oil to the replacement compressor before replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 9924 Refrigerant Oil: Fluid Type Specifications Internal Lubricant ............................................................................................................................. Poly-Alkaline Glycol (PAG) Synthetic Refrigerant Oil Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 9925 Refrigerant Oil: Service and Repair Use approved compressor oil from a closed, sealed container. When adding refrigerant oil, the transfer device and container should be clean and dry to minimize the possibility of contamination. Refrigerant oil is moisture-free and will readily absorb moisture from the air. Do not open the oil container until the service procedure requires oil. Cap the oil immediately after use. Always store compressor oil in a closed sealed container. Compressor oil left in open or improperly sealed containers will absorb moisture. Do not reuse oil that has been removed from the refrigeration system. Dispose of used oil properly, according to local regulations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications Refrigerant Pressure Sensor / Switch: Specifications A/C Refrigerant Pressure Sensor 4.7 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Component Locations > Page 9931 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 9932 A/C Refrigerant Pressure Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 9933 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Refrigerant Pressure Sensor The A/C refrigerant pressure sensor signal indicates high side refrigerant pressure to the PCM. The PCM uses this information to adjust the idle air control valve to compensate for the higher engine loads present with high A/C refrigerant pressures and to control the cooling fans. A fault in the A/C refrigerant pressure sensor signal will cause DTC P0530 Air Conditioning (A/C) Refrigerant Pressure Sensor Circuit to set. When A/C is selected the PCM increases the engine idle speed just prior to A/C clutch engagement for better idle quality. In addition the PCM will command the cooling fans on during A/C operation. The PCM monitors the A/C refrigerant pressure. If the A/C refrigerant pressure, and engine operating conditions are within a specific calibrated acceptable ranges the PCM will enable the A/C compressor relay. This is accomplished by providing a ground path for the A/C relay coil within the PCM. When the A/C compressor relay is enabled battery voltage is supplied to the compressor clutch coil. The PCM will enable the A/C compressor clutch whenever the engine is running and the A/C has been requested, unless any of the following conditions are met: ^ Throttle more than 90 percent ^ A/C head pressure more than 427 psi (4.27 volts) or less than 41 psi (0.35 volt) (as determined by the A/C refrigerant pressure sensor). ^ Ignition voltage below 9.5 volts. ^ Engine speed more than 6900 RPM for 5 seconds. ^ ECT more than 121°C (250°F). ^ IAT less than °C (32°F). For more information regarding the A/C System, refer to HVAC Compressor Controls Circuit Description in Heating and Air Conditioning. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 9934 Refrigerant Pressure Sensor / Switch: Service and Repair A/C REFRIGERANT PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. 2. Remove the air cleaner and duct assembly. 3. Disconnect the electrical connector (2) from the A/C refrigerant pressure sensor. 4. Remove the A/C refrigerant pressure sensor (1) from the liquid line. INSTALLATION PROCEDURE 1. Lubricate a new O-ring seal with mineral base 525 viscosity refrigerant oil. 2. Install the new O-ring seal. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the A/C refrigerant pressure sensor (1) to the liquid line. Tighten Tighten the A/C refrigerant pressure sensor to 4.7 N.m (41 lb in). 4. Connect the electrical connector (2) to the A/C refrigerant pressure sensor. 5. Install the air cleaner and duct assembly. 6. Connect the battery negative cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations BLOWER MOTOR RELAY Locations View The Blower Motor Relay is located in the Blower Motor Control Module (Blower Resistor Assembly) and cannot be serviced separately. The Blower Motor Control Module (Blower Resistor Assembly) is located behind the Instrument Panel (IP), on the right side of the A/C module, attached to the blower motor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 9939 Blower Motor Relay: Description and Operation HVAC BLOWER CONTROLS CIRCUIT DESCRIPTION The blower motor is a variable speed motor. The motor operates at a higher rate when voltage is increased to the maximum level. The blower motor resistors reduce the voltage supplied from the A/C FAN fuse (LH IP Accessory Wiring Junction Block) when the blower control is set at low and medium speeds (speeds 1-4). The blower motor relay is energized when the Blower Motor Control is set to the High position. This removes the blower motor resistors from the circuit and battery voltage is then applied directly from the HVAC BLO fuse (RH IP Accessory Wiring Junction Block) to the blower motor though the relay switch contacts. The blower motor then runs at high speed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Top Underhood Electrical Center Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 9943 Locations View Part of Underhood Accessory Wiring Junction Block (Top). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 9944 Compressor Clutch Relay: Description and Operation The compressor clutch coil is energized through the compressor control relay. This relay is activated by the PCM in A/C modes. The PCM provides cut-off of the relay under certain operating conditions, including wide open throttle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 9945 Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Release the retaining clip (1) and remove the engine wiring harness junction block (BOTTOM) cover (2). A/C Compressor Relay (A/C CMPR) (1) {In The Engine Wiring Harness Junction Block} 3. Remove the A/C compressor relay (A/C CMPR) (1) from the engine wiring harness junction block (BOTTOM). INSTALLATION PROCEDURE 1. Install the A/C compressor relay (A/C CM PR) (1) into the engine wiring harness junction block (BOTTOM). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 9946 2. Install the engine wiring harness junction block (BOTTOM) cover (2) and secure the retaining clip (1). 3. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Component Locations > Page 9952 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 9953 Ambient Outside Air Temperature Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 9954 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Temperature Sensor Replacement REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. 3. Disconnect the electrical connector from the ambient temperature sensor that is located on the front radiator air baffle. 4. Remove the ambient temperature sensor from the radiator air baffle. INSTALLATION PROCEDURE 1. Install the ambient temperature sensor to the radiator air baffle. 2. Connect the electrical connector to the ambient temperature sensor. 3. Lower the vehicle. 4. Connect the negative battery cable. 5. Drive the vehicle at a speed of 32 km/h (20 mph) for approximately one and a half minutes or at a speed of 72 km/h (45 mph) for approximately one minute in order to obtain the ambient update. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications Refrigerant Pressure Sensor / Switch: Specifications A/C Refrigerant Pressure Sensor 4.7 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Component Locations > Page 9960 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 9961 A/C Refrigerant Pressure Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 9962 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Refrigerant Pressure Sensor The A/C refrigerant pressure sensor signal indicates high side refrigerant pressure to the PCM. The PCM uses this information to adjust the idle air control valve to compensate for the higher engine loads present with high A/C refrigerant pressures and to control the cooling fans. A fault in the A/C refrigerant pressure sensor signal will cause DTC P0530 Air Conditioning (A/C) Refrigerant Pressure Sensor Circuit to set. When A/C is selected the PCM increases the engine idle speed just prior to A/C clutch engagement for better idle quality. In addition the PCM will command the cooling fans on during A/C operation. The PCM monitors the A/C refrigerant pressure. If the A/C refrigerant pressure, and engine operating conditions are within a specific calibrated acceptable ranges the PCM will enable the A/C compressor relay. This is accomplished by providing a ground path for the A/C relay coil within the PCM. When the A/C compressor relay is enabled battery voltage is supplied to the compressor clutch coil. The PCM will enable the A/C compressor clutch whenever the engine is running and the A/C has been requested, unless any of the following conditions are met: ^ Throttle more than 90 percent ^ A/C head pressure more than 427 psi (4.27 volts) or less than 41 psi (0.35 volt) (as determined by the A/C refrigerant pressure sensor). ^ Ignition voltage below 9.5 volts. ^ Engine speed more than 6900 RPM for 5 seconds. ^ ECT more than 121°C (250°F). ^ IAT less than °C (32°F). For more information regarding the A/C System, refer to HVAC Compressor Controls Circuit Description in Heating and Air Conditioning. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 9963 Refrigerant Pressure Sensor / Switch: Service and Repair A/C REFRIGERANT PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. 2. Remove the air cleaner and duct assembly. 3. Disconnect the electrical connector (2) from the A/C refrigerant pressure sensor. 4. Remove the A/C refrigerant pressure sensor (1) from the liquid line. INSTALLATION PROCEDURE 1. Lubricate a new O-ring seal with mineral base 525 viscosity refrigerant oil. 2. Install the new O-ring seal. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the A/C refrigerant pressure sensor (1) to the liquid line. Tighten Tighten the A/C refrigerant pressure sensor to 4.7 N.m (41 lb in). 4. Connect the electrical connector (2) to the A/C refrigerant pressure sensor. 5. Install the air cleaner and duct assembly. 6. Connect the battery negative cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Specifications Service Port HVAC: Specifications Service Port Valve Core 12 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Description and Operation Vacuum Harness HVAC: Description and Operation Vacuum lines are molded to a connector which is attached to the control knob. It is not necessary to replace the entire harness if the hoses leak or collapse. You can simply cut the hose and insert a plastic connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Specifications Vacuum Reservoir HVAC: Specifications Vacuum Tank Screws 1.5 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Specifications > Page 9973 Vacuum Reservoir HVAC: Description and Operation The vacuum supply drops during heavy acceleration. A check valve is present in the vacuum tank. The check valve maintains vacuum so that vacuum will be available for continuous use under load conditions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Specifications > Page 9974 Vacuum Reservoir HVAC: Service and Repair VACUUM TANK REPLACEMENT REMOVAL PROCEDURE 1. Remove the left and right instrument panel insulators. 2. Disconnect the vacuum hoses from the vacuum tank. 3. Remove the screws that secure the vacuum tank to the HVAC module. 4. Remove the vacuum tank. INSTALLATION PROCEDURE 1. Install the tank into the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Specifications > Page 9975 2. Install the mounting screws securing the vacuum tank. Tighten Tighten the vacuum tank screws to 1.5 N.m (13 lb in). 3. Connect the vacuum hoses to the vacuum tank. 4. Install the left and right instrument panel insulators. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System Accident With Driver Side Air Bag Deployment Component Replacement and Inspections After a collision involving a driver side air bag deployment, replace the following components on the side of the impact. If you detect any damage to the mounting points or mounting hardware, repair or replace the mounting points and mounting hardware as needed. ^ Inflatable restraint Side Impact Sensor (SIS) ^ Inflatable restraint side impact inflator module ^ Inflatable restraint Sensing and Diagnostic Module (SDM) Perform the inspections indicated above in Accident With or Without Air Bag Deployment. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair the component or replace the hardware as needed. Accident With Frontal Air Bag Deployment Component Replacement and Inspections After a collision involving air bag deployment, replace the following components. If you detect any damage to the mounting points or mounting hardware, repair or replace the mounting points and mounting hardware as needed. ^ Inflatable restraint IP module ^ Inflatable restraint steering wheel module ^ Inflatable restraint Sensing and Diagnostic Module (SDM) After a collision involving air bag deployment, inspect the Inflatable restraint steering wheel module coil and the coil wiring pigtail for melting, scorching, or other damage due to excessive heat. Perform this component inspection in addition to the inspections indicated above in Accident With or Without Air Bag Deployment. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair the component or replace the hardware as needed. Accident With/Without Air Bag Deployment CAUTION ^ Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than intended. ^ Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the side impact air bag(s) in a side impact collision or deployment of the side impact air bag(s) for conditions less severe than intended. Component Replacement and Inspections After any collision, inspect the following components as indicated. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair the component or replace the hardware as needed. ^ Steering column - Perform the steering column accident damage inspection procedures. Refer to Steering Column Accident Damage Inspection - Off Vehicle in Steering Wheel and Column - Tilt. ^ IP Knee Bolsters and Mounting Points - Inspect the knee bolsters for bending twisting, buckling, or any other type of damage. ^ IP brackets, braces, etc. - Inspect for bending, twisting, buckling, or any other type of damage. ^ Seat Belts - Perform the seat belt operational and functional checks. Refer to Operational and Functional Checks in Seat Belts. ^ IP Cross Car Beam - Inspect for bending, twisting, buckling, or any other type of damage. ^ IP Mounting Points and Brackets - Inspect for bending, twisting, buckling, or any other type of damage. ^ Seats and Seat Mounting Points - Inspect for bending, twisting, buckling, or any other type of damage. Sensor Replacement Guidelines The inflatable restraint Side Impact Sensor (SIS) replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. In this case, a moderate collision where the side of the vehicle, near the LH B pillar, is crushed, bent, or damaged due to a collision, requires replacement of the sensor. The sensor must be replaced whether a driver side air bag has deployed or if the sensor seems to be undamaged. Sensor damage which is not visible, such as a slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the sensor. Do not try to determine whether the sensor is undamaged, replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 9981 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION CAUTION: Restraint systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: - Replace any seat belt system that was in use during the collision serious enough to deploy any automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat belt systems in use by people of adult size, but seat belt systems used to secure child restraints, infant carriers and booster seats, including LATCH system and top tether anchorages. - Replace any seat belt system that has torn, worn, or damaged components. This not only includes adult seat belt systems, but built-in child restraints and LATCH system components, if any. - Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible. - Replace any seat belt system if you are doubtful about its condition. This not only includes adult seat belt systems, but built-in child restraints, LATCH system components, and any restraint system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single seat belt system components in vehicles that have been in a collision as described above. Always replace the entire seat belt system with the buckle, guide and retractor assembly, which includes the latch and webbing material. After a minor collision where no automatic restraint device was deployed, seat belt system replacement may not be necessary, unless some of the parts are torn, worn, or damaged. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 9982 Repairs and Inspections Required After a Collision: Service and Repair Steering Column Inspection Procedure - Vehicles involved in accidents resulting in frame damage, major body or sheet metal damage, or where the steering column has been impacted, or where supplemental inflatable restraint systems deployed may also have a damaged or misaligned steering column. - Check the capsules on the steering column bracket assembly: all must be securely seated in the bracket slots and checked for any loose conditions when pushed or pulled by hand. If not, the bracket should be replaced if bolted to the jacket assembly. If the bracket is welded to the jacket assembly replace the jacket assembly. - Check for jacket assembly collapse by measuring the distance from the lower edge of the upper jacket to a defined point on the lower jacket. If measured dimensions are not within specifications, a new jacket must be installed. - Visually inspect steering shaft for sheared injected plastic (1). If steering shaft shows sheared plastic, a new steering shaft must be installed. - Any frame damage that could cause a bent steering shaft must have the steering shaft runout checked in the following manner. Using a dial indicator at the lower end of the steering shaft, have the steering wheel rotated. Runout must not exceed 1.60 mm. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions CAUTION: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserve energy supply. The reserve energy supply provides deployment power for the air bags. Deployment power is available for as much as 10 seconds after disconnecting the vehicle power by any of the following methods: ^ Turn OFF the ignition. ^ Remove the fuse that provides power to the SDM. ^ Disconnect the vehicle battery from the vehicle electrical system. Disabling the SIR system prevents deploying of the air bags from the reserve energy supply power. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the LH instrument panel access hole cover. 5. Remove the SDM Fuse from the fuse block. IMPORTANT: With the SDM Fuse removed and the ignition ON, The AIR BAG warning lamp illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the RH instrument panel access hole cover. 7. Unclip the frontal air bags yellow 4-way connector from the metal rail. 8. Remove the Connector Position Assurance (CPA) from the frontal air bags yellow 4-way connector. 9. Disconnect the frontal air bags yellow 4-way connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 9989 10. Remove the connector position assurance (CPA) from the driver side air bag yellow 2-way connector (4) located under the driver seat, if the vehicle is equipped with a driver side air bag. 11. Disconnect the driver side air bag yellow 2-way connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 9990 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Connect the driver side air bag yellow 2-way connector (4) located under the driver seat, if the vehicle is equipped with a driver side air bag. 2. Install the CPA to the driver side air bag yellow 2-way connector. 3. Connect the frontal air bags yellow 4-way connector located at the RH side of the instrument panel. 4. Install the CPA to the frontal air bags yellow 4-way connector. 5. Connect the frontal air bags yellow 4-way connector to the metal rail. 6. Instal the RH instrument panel access hole cover. 7. Install the SDM fuse to the LH fuse block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 9991 8. Install the LH instrument panel access hole cover. 9. Staying well away from the airbags, turn ON the ignition. 9.1. The AIR BAG warning lamp will flash seven times. 9.2. The AIR BAG warning lamp will then turn OFF. 10. Perform A Diagnostic System Check SIR if the AIR BAG warning lamp does not operate as described. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls for Air Bag: > NHTSA00V371000 > Nov > 00 > Recall 00V371000: Air Bag Inflator May Separate Air Bag: Recalls Recall 00V371000: Air Bag Inflator May Separate Some of these vehicles exhibit a condition in which the driver side impact air bag inflator separates from the air bag module during deployment. If the inflator separates, the air bag will not deploy properly during a crash and occupant protection would be reduced. If is also possible that a separated inflator could be propelled downward and could result in injury to a rear seat passenger whose foot is positioned approximately under the inflator module . Dealers will replace the side impact air bag module. Owner notification is expected to begin during December 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or Buick at 1-800-521-7300. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > NHTSA00V371000 > Nov > 00 > Recall 00V371000: Air Bag Inflator May Separate Air Bag: All Technical Service Bulletins Recall 00V371000: Air Bag Inflator May Separate Some of these vehicles exhibit a condition in which the driver side impact air bag inflator separates from the air bag module during deployment. If the inflator separates, the air bag will not deploy properly during a crash and occupant protection would be reduced. If is also possible that a separated inflator could be propelled downward and could result in injury to a rear seat passenger whose foot is positioned approximately under the inflator module . Dealers will replace the side impact air bag module. Owner notification is expected to begin during December 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or Buick at 1-800-521-7300. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 10005 Air Bag: Specifications Inflatable Restraint IP Module Fasteners 10 Nm Inflatable Restraint Side Impact Sensor (LH) (SIS) Fasteners 10 Nm Inflatable Restraint Side Impact Module (LH) Fasteners 5 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations Air Bag: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations > Page 10008 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations > Page 10009 Air Bag: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations > Page 10010 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations > Page 10011 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations > Page 10012 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Inflatable Restraint Front Side Impact Module-LH (AJ7) Inflatable Restraint Front Side Impact Module - LH (AJ7) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Inflatable Restraint Front Side Impact Module-LH (AJ7) > Page 10015 Inflatable Restraint IP Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Page 10016 Air Bag: Description and Operation INFLATOR MODULES The inflator modules consist of an inflatable bag and an inflator. An inflator consists of a canister of gas-generating material and an initiating device. The initiator is part of the deployment loop. When the vehicle is in a frontal crash of sufficient force, the inflatable restraint Sensing and Diagnostic Module (SDM)causes current to flow through the frontal air bag deployment loops. When the vehicle is in a side impact crash of sufficient force, the SDM causes current to flow through the appropriate side impact air bag deployment loop. Current passing through the initiator ignites the material in the inflator module. The gas produced from this reaction rapidly inflates the air bag. There is a shorting bar on the inflatable restraint steering wheel module side of the upper steering column connector that connects the inflatable restraint steering wheel module coil to the inflatable restraint steering wheel module. The shorting bar shorts across the inflatable restraint steering wheel module circuits during the disconnection of the upper steering column connector. The shorting of the inflatable restraint steering wheel module circuitry will help prevent unwanted deployment of the air bag when servicing the inflatable restraint steering wheel module, the steering column or other SIR system components. There is a shorting bar on the inflatable restraint IP module connector that connects to the SIR wiring harness. The shorting bar shorts across the inflatable restraint IP module circuits during the disconnection of the inflatable restraint IP module connector. The shorting of the inflatable restraint IP module circuitry will help prevent unwanted deployment of the air bag when servicing the inflatable restraint IP module, the instrument panel or other SIR system components. There is a shorting bar on the inflatable restraint front side impact module (LH) connector located under the driver seat that connects to the SIR wiring harness. The shorting bar shorts across the inflatable restraint front side impact module (LH) circuit during the disconnection of the inflatable restraint front side impact module (LH) connector. The shorting of the side air bag module circuitry will help prevent unwanted deployment of the side air bag when servicing the inflatable restraint front side impact module (LH), the driver seat or other SIR system components. There is a shorting bar on the inflatable restraint front side impact module (RH) connector located under the passenger seat that connects to the SIR wiring harness. The shorting bar shorts across the inflatable restraint front side impact module (RH) circuit during the disconnection of the inflatable restraint front side impact module (RH) connector. The shorting of the side air bag module circuitry will help prevent unwanted deployment of the side air bag when servicing the inflatable restraint front side impact module (RH), the passenger seat or other SIR system components. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping Air Bag: Service and Repair Handling/Shipping/Scrapping Handling a Deployed Steering Wheel Inflator Module After the inflator module has deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates), and by-products of the chemical reaction. The deployment reaction produces sodium hydroxide dust (similar to lye soap). The sodium hydroxide quickly reacts with the atmospheric moisture. This atmospheric moisture converts the sodium hydroxide into sodium carbonate and sodium bicarbonate (baking soda). Therefore, you will probably find no sodium hydroxide present after the deployment. Gloves and safety glasses are recommended, however, as a precaution. Gloves and safety glasses help to prevent possible irritation of the skin or eyes. Inflator Module Handling, Shipping, and Scrapping LIVE (UNDEPLOYED) INFLATOR MODULE CAUTION: Refer to Inflator Module Handling And Storage Caution in Service Precautions. Be careful when you handle or store a live (undeployed) inflator module. An air bag deployment produces rapid gas generation. This may cause the inflator module or an object in front of the inflator module to jettison through the air in the event of an unlikely deployment. SHIPPING PROCEDURES Refer to the latest service bulletins for proper SIR inflator module shipping procedures. SCRAPPING PROCEDURE During the course of a vehicle's useful life, certain situations may arise which will require the disposal of a live (undeployed) inflator module. The following information covers the proper procedures for this disposal. Deploy the inflator module before disposal. Do not dispose the module through normal disposal channels. CAUTION: Refer to Inflator Module Disposal Caution in Service Precautions. Do NOT deploy an air bag in the following situations: ^ After replacing an inflator module under warranty, the module may need to be returned undeployed to the original manufacturer. Refer to the latest service bulletin regarding SIR shipping procedures. ^ If the vehicle is the subject of a Product Liability report related to the SIR system and is subject to a Preliminary Investigation (GM-1241), do not alter the SIR system in any manner. Refer to the latest service bulletin on SIR shipping procedures. ^ If the vehicle is involved in a campaign affecting the inflator modules, follow the instructions in the Campaign Service Bulletin for proper SIR handling and shipping procedures. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10019 Air Bag: Service and Repair Deployment Procedures General Information You may deploy the inflator module inside or outside of the vehicle. The method used depends upon the final disposition of the vehicle. Review the following procedures in order to determine which will work best in a given situation Inflatable Restraint Steering Wheel Module TOOLS REQUIRED ^ J 38826 SIR Deployment Harness ^ An appropriate pigtail adapter CAUTION ^ Refer to Inflator Module Disposal Caution in Service Precautions. ^ When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Deploy the inflatable restraint steering wheel module outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: ^ Using the SIR diagnostics, you determine that the inflator module does not function properly. ^ The inflator module is scratched or ripped on the cover. ^ The inflator module pigtail harness is damaged. ^ The inflator module connector is damaged. ^ An inflator module connector terminal is damaged. Deployment and disposal of a malfunctioning inflator module is subject to any required retention period. 1. Turn OFF the ignition. 2. Remove the key from the ignition switch. 3. Put on safety glasses. 4. Inspect J 38826 and the appropriate pigtail adaptor for damage. Replace as needed. 5. Short the two SIR deployment harness (1) leads together using one banana plug seated into the other. 6. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). 7. Remove the inflatable restraint steering wheel module from the vehicle. CAUTION: Refer to Inflator Module Handling And Storage Caution in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10020 8. Place the module on a work bench, with the vinyl trim cover facing up and away from the surface. 9. Clear a space on the ground about 1.85 M (6 ft) in diameter for deployment of the module. If possible, use a paved, outdoor location free of activity. Otherwise use a space free of activity on the shop floor. Verify that you have sufficient ventilation. 10. Clear all loose or flammable objects from the area. 11. Place the module in the center of the space with the vinyl trim cover facing up. 12. Extend the SIR deployment harness and adapter to full length from the module. 13. Place a 12-V minimum, 2-A minimum power source (e.g., a vehicle battery) near the shorted end of the harness. 14. Connect the module (1) to the adapter (2) on the SIR deployment harness (3). 15. Firmly seat the adapter into the module connector. 16. Clear the area of people. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10021 17. Separate the two banana plugs on the SIR deployment harness. IMPORTANT ^ The rapid gas expansion involved with deploying an air bag is very loud. Notify all people in the immediate area that you intend to deploy the inflator module. ^ When the air bag deploys, the inflator module may jump about 30 cm (1 ft) vertically. This is a normal reaction of the inflator module to the force of the rapid gas expansion inside the air bag. 18. Connect the SIR deployment harness wires to the power source. 19. Disconnect the SIR deployment harness from the power source after the air bag deploys. 20. Seat one banana plug into the other in order to short the deployment harness leads. 21. If the air bag did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, continue performing the following steps. CAUTION: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury: ^ Allow sufficient time for cooling before touching any metal surface of the inflator module. ^ Do not place the deployed inflator module near any flammable objects. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10022 22. Put on a pair of shop gloves. 23. Disconnect the pigtail adapter from the inflator module as soon as possible. 24. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed. 25. Dispose of the deployed module through normal refuse channels. 26. Wash your hands with a mild soap. Inflatable Restraint I/P Module TOOLS REQUIRED ^ J 39401-B Sir Deployment Fixture ^ J 38826 Sir Deployment Harness ^ An appropriate pigtail adapter CAUTION ^ Refer to Inflator Module Disposal Caution in Service Precautions. ^ When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Deploy the inflatable restraint instrument panel inflator module outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: ^ Using the SIR diagnostics, you determine that the inflator module does not function properly. ^ The inflator module is scratched or ripped on the cover. ^ The inflator module pigtail (if equipped) is damaged. ^ The inflator module connector is damaged. ^ An inflator module connector terminal is damaged. Deployment and disposal of a malfunctioning inflator module is subject to any required retention period. IMPORTANT: Refer to the latest General Motors Service Bulletins before deploying a passenger inflator module. 1. Turn OFF the ignition. 2. Remove the key from the ignition switch. 3. Put on safety glasses. 4. Inspect J 38826 and the appropriate pigtail adapter for damage. Replace as needed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10023 5. Short the two SIR deployment harness (1) leads together using one banana plug seated into the other. 6. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). 7. Remove the inflatable restraint instrument panel module. CAUTION: Refer to Inflator Module Handling And Storage Caution in Service Precautions. 8. Place the module on a work bench, with the vinyl trim cover facing up and away from the surface. 9. Clear a space on the ground about 1.85 M (6 ft) in diameter for deployment of the module. If possible, use a paved, outdoor location free of activity. Otherwise use a space free of activity on the shop floor. Verify that you have sufficient ventilation. 10. Clear all loose or flammable objects from the area. 11. Place J 39401-B in the center of the cleared area. 12. Fill the fixture plastic reservoir with water or sand. IMPORTANT: Securely hand tighten all fasteners prior to deployment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10024 13. Secure the J 39401-7A arms (5) to J39401-B (2) using carriage bolts (3) and nuts (4). 14. Mount the module (1) in J39401-B with the vinyl trim cover facing up. 15. To mount, use four M6 bolts (6), nuts (8), and washers (7) in order to secure the module (1) to the deployment fixture (2). 16. Extend the SIR deployment harness and adapter to full length from the module. 17. Place a 12-V minimum, 2-A minimum power source (e.g., a vehicle battery) near the shorted end of the harness. 18. Connect the module (1) to the adapter (2) on the SIR deployment harness (3). 19. Firmly seat the adapter into the module connector. 20. Clear the area of people. CAUTION: When you are deploying an inflator module for disposal perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10025 21. Separate the two banana plugs on the SIR deployment harness. IMPORTANT ^ The rapid gas expansion involved with deploying an air bag is very loud. Notify all the people in the immediate area that you intend to deploy the inflator module. ^ When the air bag deploys, the SIR deployment fixture may jump vertically. This is a normal reaction of the inflator module to the force of the rapid gas expansion inside the air bag. 22. Connect the SIR deployment harness wires to the power source. 23. Disconnect the SIR deployment harness from the power source after the air bag deploys. 24. Seat one banana plug into the other in order to short the deployment harness leads. 25. If the air bag did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps. CAUTION: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury: ^ Allow sufficient time for cooling before touching any metal surfaces of the inflator module. ^ Do not place the deployed inflator module near any flammable objects. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10026 26. Put on a pair of shop gloves. 27. Disconnect the pigtail adapter from the inflator module as soon as possible. 28. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed. 29. Dispose of the deployed module through normal refuse channels. 30. Wash your hands with a mild soap. Inflatable Restraint Side Impact Module TOOLS REQUIRED ^ J 39401-B SIR Deployment Fixture ^ J 38826 SIR Deployment Harness ^ An appropriate pigtail adapter CAUTION ^ Refer to inflator Module Disposal Caution in Service Precautions. ^ When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Deploy the inflatable restraint side impact inflator module outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: ^ Using the SIR diagnostics, you determine that the inflator module does not function properly. ^ The inflator module is scratched or ripped on the cover. ^ The inflator module pigtail (if equipped) is damaged. ^ The inflator module connector is damaged. ^ An inflator module connector terminal is damaged. Deployment and disposal of a malfunctioning inflator module is subject to any required retention period. IMPORTANT: Refer to the latest General Motors Service Bulletins before deploying a side impact inflator module. 1. Turn OFF the ignition. 2. Remove the key from the ignition switch. 3. Put on safety glasses. 4. Inspect J 38826 and the appropriate pigtail adapter for damage. Replace as needed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10027 5. Short the two SIR deployment harness (1) leads together using one banana plug seated into the other. 6. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). 7. Remove the inflatable restraint side impact module. CAUTION: Refer to Inflator Module Handling And Storage Caution in Service Precautions. 8. Place the module on a work bench, with the vinyl trim cover facing up and away from the surface. 9. Clear a space on the ground about 1.85 M (6 ft) in diameter for deployment of the module. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Verify that you have sufficient ventilation. 10. Clear all loose or flammable objects from the area. 11. Place J 39401-B in the center of the cleared area. 12. Fill the fixture plastic reservoir with water or sand. IMPORTANT: Securely hand tighten all fasteners prior to deployment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10028 13. Mount the module (1) in J39401-B (3) with the vinyl trim cover facing up. 14. To mount, use two M6 x 1.0 nuts (2) with washers in order to secure the module (1) to the deployment fixture (3). 15. Extend the SIR deployment harness and adapter to full length from the module. 16. Place a 12-V minimum, 2-A minimum power source (e.g., vehicle battery) near the shorted end of the harness. 17. Connect the module (1) to the adapter (2) on the SIR deployment harness (3). 18. Firmly seat the adapter into the module connector. 19. Clear the area of people. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10029 20. Separate the two banana plugs on the SIR deployment harness. IMPORTANT ^ The rapid gas expansion involved with deploying an air bag is very loud. Notify all the people in the immediate area that you intend to deploy the inflator module. ^ When the air bag deploys, the SIR deployment fixture may jump vertically. This is a normal reaction of the inflator module to the force of the rapid gas expansion inside the air bag. 21. Connect the SIR deployment harness wires to the power source. 22. Disconnect the SIR deployment harness from the power source after the air bag deploys. 23. Seat one banana plug into the other in order to short the deployment harness leads. 24. If the air bag did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps. CAUTION: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10030 ^ Allow sufficient time for cooling before touching any metal surface of the inflator module. ^ Do not place the deployed inflator module near any flammable objects. 25. Put on a pair of shop gloves. 26. Disconnect the pigtail adapter from the inflator module as soon as possible. 27. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed. 28. Dispose of the deployed module through normal refuse channels. 29. Wash hands with a mild soap. Side Air Bags (Vehicle Scrapping Procedure) You may deploy the inflator modules inside the vehicle prior to destroying the vehicle or when salvaging the vehicle for parts. This includes but is not limited to the following situations: ^ The vehicle has completed its useful life. ^ Irreparable damage has occurred to the vehicle in a non-deployment type accident. ^ Irreparable damage has occurred to the vehicle during a theft. ^ The vehicle is being salvaged for parts to be used on a vehicle with a different VIN, as opposed to rebuilding the vehicle as the same VIN. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed Failure to follow the procedures in the order listed may result in personal injury. 1. Turn the ignition switch to the OFF position. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove all loose objects from the front seats. 5. Disconnect the inflatable restraint front side impact module (LH) yellow 2-way connector located under the driver seat. 6. Cut the yellow 2-way harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 7. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10031 8. Cut two 4.6-M (15-ft) deployment wires from a multi-strand wire 0.8 sq.mm (18 gage) or thicker. Use these wires to fabricate the driver deployment harness. 9. Strip 13 mm (0.5 in) of insulation from both ends of these wires. 10. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the air bag. 11. Twist together one connector wire lead to one deployment wire. 12. Inspect that the previous connection is secure. 13. Bend flat the twisted connection. 14. Secure and insulate the connection using electrical tape. 15. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 16. Connect the deployment harness to the inflatable restraint front side impact module (LH) yellow 2-way connector. 17. Route the deployment harness out of the vehicle's driver side. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10032 18. Disconnect the inflatable restraint front side impact module (RH) yellow 2-way harness connector located under the front passenger seat. 19. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 20. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 21. Cut two 4.6-M (15-ft) deployment wires from a multi-strand wire 0.8 sq.mm (18 gage) or thicker. These wires will be used to fabricate the passenger deployment harness. 22. Strip 13 mm (0.5 in) of insulation from both ends of these wires. 23. Twist together one end from each of the wires in order to short the wires. 24. Twist together one connector wire lead to one deployment wire. 25. Bend flat the twisted connection. 26. Secure and insulate the connection using electrical tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10033 27. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 28. Connect the deployment harness to the inflatable restraint front side impact module (RH) yellow 2-way connector. 29. Route the deployment harness out of the passenger side of the vehicle. 30. Clear the inside and outside of the vehicle of any people or loose and flammable objects. 31. Stretch the driver harness to full length. 32. Stretch the passenger harness to full length. 33. Completely cover the windshield and front door window openings with a drop cloth. 34. Place a power source, 12 V minimum, 2 A minimum (e.g., a vehicle battery) near the shorted end of the harness. 35. Separate the two ends of the driver side air bag deployment harness wires. 36. Connect the driver side air bag deployment harness wires to the power source in order to deploy the inflatable restraint front side impact module (LH). 37. Disconnect the driver side air bag deployment harness wires from the power source. 38. Separate the two ends of the passenger side air bag deployment harness wires. 39. Connect the passenger side air bag deployment harness wires to the power source in order to deploy the inflatable restraint front side impact (RH) module. 40. Disconnect the passenger side air bag deployment harness wires from the power source. 41. Twist together one end of each wire on the driver side air bag deployment harness in order to short the wires. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10034 42. Twist together one end of each wire on the passenger side air bag deployment harness in order to short the wires. 43. Remove the drop cloth from the vehicle. 44. Disconnect both harnesses from the vehicle. 45. Discard the harnesses. 46. Scrap the vehicle in the same manner as a non-SIR equipped vehicle. 47. If one or both of the modules did not deploy, perform the following steps: 47.1. Remove the undeployed modules from the vehicle. 47.2. Temporarily store the modules. 47.3. Call the Technical Assistance Group for further assistance. Frontal Air Bags (Vehicle Scrapping Procedure) You may deploy the inflator modules inside the vehicle prior to destroying the vehicle or when salvaging the vehicle for parts. This includes but is not limited to the following situations: ^ The vehicle has completed its useful life. ^ Irreparable damage has occurred to the vehicle in a non-deployment type accident. ^ Irreparable damage has occurred to the vehicle during a theft. ^ The vehicle is being salvaged for parts to be used on a vehicle with a different VIN, as opposed to rebuilding the vehicle as the same VIN. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. 1. Turn the ignition switch to the OFF position. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove all loose objects from the front seats. 5. Disconnect the inflatable restraint steering wheel module yellow 2-way connector. 6. Cut the yellow 2-way harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 7. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 8. Cut two 4.6-M (15-ft) deployment wires from a multi-strand wire 0.8 sq. mm (18 gage) or thicker. Use these wires to fabricate the driver frontal air bag deployment harness. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10035 9. Strip 13 mm (0.5 in) of insulation from both ends of these wires. 10. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the air bag. 11. Twist together one connector wire lead to one deployment wire. 12. Inspect that the previous connection is secure. 13. Bend flat the twisted connection. 14. Secure and insulate the connection using electrical tape. 15. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 16. Connect the deployment harness to the inflatable restraint steering wheel module yellow 2-way connector. 17. Route the deployment harness out of the vehicle's driver side. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10036 18. Disconnect the inflatable restraint IP module yellow 2-way harness connector. 19. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 20. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 21. Cut two 6.1-M (20-ft) deployment wires from a multi-strand wire 0.8 sq.mm (18 gage) or thicker. These wires will be used to fabricate the passenger deployment harness. 22. Strip 13 mm (0.5 in) of insulation from both ends of these wires. 23. Twist together one end from each of the wires in order to short the wires. 24. Twist together one connector wire lead to one deployment wire. 25. Bend flat the twisted connection. 26. Secure and insulate the connection using electrical tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10037 27. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 28. Connect the deployment harness to the inflatable restraint IP module yellow 2-way connector. 29. Route the deployment harness out of the passenger side of the vehicle. 30. Clear the inside and outside of the vehicle of any people or loose and flammable objects. 31. Stretch the driver harness to full length. 32. Stretch the passenger harness to full length. 33. Completely cover the windshield and front door window openings with a drop cloth. 34. Place a power source, 12 V minimum, 2 A minimum (e.g., a vehicle battery) near the shorted end of the harness. 35. Separate the two ends of the driver frontal air bag deployment harness wires. 36. Connect the driver frontal air bag deployment harness wires to the power source in order to deploy the inflatable restraint steering wheel module. 37. Disconnect the driver frontal air bag deployment harness wires from the power source. 38. Separate the two ends of the passenger frontal air bag deployment harness wires. 39. Connect the passenger frontal air bag deployment harness wires to the power source in order to deploy the inflatable restraint IP module. 40. Disconnect the passenger frontal air bag deployment harness wires from the power source. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10038 41. Twist together one end of each wire on the driver frontal air bag deployment harness in order to short the wires. 42. Twist together one end of each wire on the passenger frontal air bag deployment harness in order to short the wires. 43. Remove the drop cloth from the vehicle. 44. Disconnect both harnesses from the vehicle. 45. Discard the harnesses. 46. Scrap the vehicle in the same manner as a non-SIR equipped vehicle. 47. If one or both of the modules did not deploy, perform the following steps: 47.1. Remove the undeployed modules from the vehicle. 47.2. Temporarily store the modules. 47.3. Call the Technical Assistance Group for further assistance. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10039 Air Bag: Service and Repair Repair Instructions Inflatable Restraint Instrument Panel Module Replacement CAUTION: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module ^ Make sure the bag opening points away from you When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the instrument panel upper trim pad. 3. Remove the Connector Position Assurance (CPA) from the inflatable restraint IP module yellow 2-way wiring harness connector. 4. Disconnect the inflatable restraint IP module yellow 2-way wiring harness connector. 5. Remove the inflatable restraint IP module mounting fasteners (3). 6. Remove the inflatable restraint IP module (1) from the cross-car beam (2). INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10040 1. Install the inflatable restraint IP module (1) to the cross-car beam (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the inflatable restraint IP module mounting fasteners (3). Tighten Tighten fasteners to 10 N.m (89 lb in). 3. Connect the inflatable restraint IP module yellow 2-way wiring harness connector. 4. Install the CPA to the inflatable restraint IP module yellow 2-way wiring harness connector. 5. Install the instrument panel upper trim pad. 6. Enable the SIR system. Refer to Enabling the SIR System. Inflatable Restraint Steering Wheel Module Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10041 2. Insert a flat-bladed screwdriver into one of the four openings in the back of the steering wheel. 3. Turn the screwdriver counterclockwise to disengage the spring from the slot in the module. 4. Pull the module gently away from the steering wheel. 5. Repeat the previous three steps for the remaining openings. 6. Remove the inflator module from the steering wheel. 7. Remove the Connector Position Assurance (CPA) from the driver frontal air bag electrical connector. 8. Disconnect the electrical connector from the back of the module. 9. Rotate the horn contact lead counterclockwise 1/4 turn in order to remove the horn contact lead from the steering column cam tower. INSTALLATION PROCEDURE 1. Install the horn contact lead to the steering column cam tower. 2. Connect the electrical connector to the back of the module. 3. Install the CPA to the module electrical connector. 4. Install the module to the steering wheel by pushing on both the right and left sides of the inflator module until the retaining springs engage. 5. Enable the SIR system. Refer to Enabling the SIR System. Inflatable Restraint Side Impact Module Replacement - Front REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the driver seat. 3. Unclip the J-clip that is along the lower rear seat back. 4. Remove the seat back cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10042 5. Remove the driver side air bag fasteners (2). 6. Note the routing of the driver side air bag wiring harness (4) and retaining clip attachments within the driver seat. 7. Remove the driver side air bag wiring harness (4) retaining clips from the driver seat frame. 8. Gently pull the pigtail harness up into the seat back while guiding the harness through the wire triangle of the seat frame. 9. Remove the module (1) from the driver seat back frame. INSTALLATION PROCEDURE 1. Install the module (1) to the seat while guiding the pigtail harness through the trim cup. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the driver side air fasteners (2). Tighten Tighten the driver side air bag fasteners to 10 N.m (89 lb in). 3. Gently pull the driver side air bag wiring harness (4) down into the seat cushion while guiding the harness through the wire triangle of the seat frame. 4. Install the harness retaining clips to the seat frame. 5. Install the seat back cover. 6. Connect together the J-clip that is along the lower rear seat back. 7. Install the driver seat. 8. Enable the SIR system. Refer to Enabling the SIR System. Inflator Module Handling, Shipping, and Scrapping LIVE (UNDEPLOYED) INFLATOR MODULE CAUTION: Refer to Inflator Module Handling And Storage Caution in Service Precautions. Be careful when you handle or store a live (undeployed) inflator module. An air bag deployment produces rapid gas generation. This may cause the inflator module or an object in front of the inflator module to jettison through the air in the event of an unlikely deployment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10043 SHIPPING PROCEDURES Refer to the latest service bulletins for proper SIR inflator module shipping procedures. SCRAPPING PROCEDURE During the course of a vehicle's useful life, certain situations may arise which will require the disposal of a live (undeployed) inflator module. The following information covers the proper procedures for this disposal. Deploy the inflator module before disposal. Do not dispose the module through normal disposal channels. CAUTION: Refer to Inflator Module Disposal Caution in Service Precautions. Do NOT deploy an air bag in the following situations: ^ After replacing an inflator module under warranty, the module may need to be returned undeployed to the original manufacturer. Refer to the latest service bulletin regarding SIR shipping procedures. ^ If the vehicle is the subject of a Product Liability report related to the SIR system and is subject to a Preliminary Investigation (GM-1241), do not alter the SIR system in any manner. Refer to the latest service bulletin on SIR shipping procedures. ^ If the vehicle is involved in a campaign affecting the inflator modules, follow the instructions in the Campaign Service Bulletin for proper SIR handling and shipping procedures. General Information You may deploy the inflator module inside or outside of the vehicle. The method used depends upon the final disposition of the vehicle. Review the following procedures in order to determine which will work best in a given situation Inflatable Restraint Steering Wheel Module TOOLS REQUIRED ^ J 38826 SIR Deployment Harness ^ An appropriate pigtail adapter CAUTION ^ Refer to Inflator Module Disposal Caution in Service Precautions. ^ When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Deploy the inflatable restraint steering wheel module outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: ^ Using the SIR diagnostics, you determine that the inflator module does not function properly. ^ The inflator module is scratched or ripped on the cover. ^ The inflator module pigtail harness is damaged. ^ The inflator module connector is damaged. ^ An inflator module connector terminal is damaged. Deployment and disposal of a malfunctioning inflator module is subject to any required retention period. 1. Turn OFF the ignition. 2. Remove the key from the ignition switch. 3. Put on safety glasses. 4. Inspect J 38826 and the appropriate pigtail adaptor for damage. Replace as needed. 5. Short the two SIR deployment harness (1) leads together using one banana plug seated into the other. 6. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10044 7. Remove the inflatable restraint steering wheel module from the vehicle. CAUTION: Refer to Inflator Module Handling And Storage Caution in Service Precautions. 8. Place the module on a work bench, with the vinyl trim cover facing up and away from the surface. 9. Clear a space on the ground about 1.85 M (6 ft) in diameter for deployment of the module. If possible, use a paved, outdoor location free of activity. Otherwise use a space free of activity on the shop floor. Verify that you have sufficient ventilation. 10. Clear all loose or flammable objects from the area. 11. Place the module in the center of the space with the vinyl trim cover facing up. 12. Extend the SIR deployment harness and adapter to full length from the module. 13. Place a 12-V minimum, 2-A minimum power source (e.g., a vehicle battery) near the shorted end of the harness. 14. Connect the module (1) to the adapter (2) on the SIR deployment harness (3). 15. Firmly seat the adapter into the module connector. 16. Clear the area of people. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10045 CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. 17. Separate the two banana plugs on the SIR deployment harness. IMPORTANT ^ The rapid gas expansion involved with deploying an air bag is very loud. Notify all people in the immediate area that you intend to deploy the inflator module. ^ When the air bag deploys, the inflator module may jump about 30 cm (1 ft) vertically. This is a normal reaction of the inflator module to the force of the rapid gas expansion inside the air bag. 18. Connect the SIR deployment harness wires to the power source. 19. Disconnect the SIR deployment harness from the power source after the air bag deploys. 20. Seat one banana plug into the other in order to short the deployment harness leads. 21. If the air bag did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, continue performing the following steps. CAUTION: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury: ^ Allow sufficient time for cooling before touching any metal surface of the inflator module. ^ Do not place the deployed inflator module near any flammable objects. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10046 22. Put on a pair of shop gloves. 23. Disconnect the pigtail adapter from the inflator module as soon as possible. 24. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed. 25. Dispose of the deployed module through normal refuse channels. 26. Wash your hands with a mild soap. Inflatable Restraint IP Module TOOLS REQUIRED ^ J 39401-B Sir Deployment Fixture ^ J 38826 Sir Deployment Harness ^ An appropriate pigtail adapter CAUTION ^ Refer to Inflator Module Disposal Caution in Service Precautions. ^ When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Deploy the inflatable restraint instrument panel inflator module outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: ^ Using the SIR diagnostics, you determine that the inflator module does not function properly. ^ The inflator module is scratched or ripped on the cover. ^ The inflator module pigtail (if equipped) is damaged. ^ The inflator module connector is damaged. ^ An inflator module connector terminal is damaged. Deployment and disposal of a malfunctioning inflator module is subject to any required retention period. IMPORTANT: Refer to the latest General Motors Service Bulletins before deploying a passenger inflator module. 1. Turn OFF the ignition. 2. Remove the key from the ignition switch. 3. Put on safety glasses. 4. Inspect J 38826 and the appropriate pigtail adapter for damage. Replace as needed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10047 5. Short the two SIR deployment harness (1) leads together using one banana plug seated into the other. 6. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). 7. Remove the inflatable restraint instrument panel module. CAUTION: Refer to Inflator Module Handling And Storage Caution in Service Precautions. 8. Place the module on a work bench, with the vinyl trim cover facing up and away from the surface. 9. Clear a space on the ground about 1.85 M (6 ft) in diameter for deployment of the module. If possible, use a paved, outdoor location free of activity. Otherwise use a space free of activity on the shop floor. Verify that you have sufficient ventilation. 10. Clear all loose or flammable objects from the area. 11. Place J 39401-B in the center of the cleared area. 12. Fill the fixture plastic reservoir with water or sand. IMPORTANT: Securely hand tighten all fasteners prior to deployment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10048 13. Secure the J 39401-7A arms (5) to J39401-B (2) using carriage bolts (3) and nuts (4). 14. Mount the module (1) in J39401-B with the vinyl trim cover facing up. 15. To mount, use four M6 bolts (6), nuts (8), and washers (7) in order to secure the module (1) to the deployment fixture (2). 16. Extend the SIR deployment harness and adapter to full length from the module. 17. Place a 12-V minimum, 2-A minimum power source (e.g., a vehicle battery) near the shorted end of the harness. 18. Connect the module (1) to the adapter (2) on the SIR deployment harness (3). 19. Firmly seat the adapter into the module connector. 20. Clear the area of people. CAUTION: When you are deploying an inflator module for disposal perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10049 21. Separate the two banana plugs on the SIR deployment harness. IMPORTANT ^ The rapid gas expansion involved with deploying an air bag is very loud. Notify all the people in the immediate area that you intend to deploy the inflator module. ^ When the air bag deploys, the SIR deployment fixture may jump vertically. This is a normal reaction of the inflator module to the force of the rapid gas expansion inside the air bag. 22. Connect the SIR deployment harness wires to the power source. 23. Disconnect the SIR deployment harness from the power source after the air bag deploys. 24. Seat one banana plug into the other in order to short the deployment harness leads. 25. If the air bag did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps. CAUTION: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury: ^ Allow sufficient time for cooling before touching any metal surfaces of the inflator module. ^ Do not place the deployed inflator module near any flammable objects. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10050 26. Put on a pair of shop gloves. 27. Disconnect the pigtail adapter from the inflator module as soon as possible. 28. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed. 29. Dispose of the deployed module through normal refuse channels. 30. Wash your hands with a mild soap. Inflatable Restraint Side Impact Module TOOLS REQUIRED ^ J 39401-B SIR Deployment Fixture ^ J 38826 SIR Deployment Harness ^ An appropriate pigtail adapter CAUTION ^ Refer to inflator Module Disposal Caution in Service Precautions. ^ When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Deploy the inflatable restraint side impact inflator module outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: ^ Using the SIR diagnostics, you determine that the inflator module does not function properly. ^ The inflator module is scratched or ripped on the cover. ^ The inflator module pigtail (if equipped) is damaged. ^ The inflator module connector is damaged. ^ An inflator module connector terminal is damaged. Deployment and disposal of a malfunctioning inflator module is subject to any required retention period. IMPORTANT: Refer to the latest General Motors Service Bulletins before deploying a side impact inflator module. 1. Turn OFF the ignition. 2. Remove the key from the ignition switch. 3. Put on safety glasses. 4. Inspect J 38826 and the appropriate pigtail adapter for damage. Replace as needed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10051 5. Short the two SIR deployment harness (1) leads together using one banana plug seated into the other. 6. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). 7. Remove the inflatable restraint side impact module. CAUTION: Refer to Inflator Module Handling And Storage Caution in Service Precautions. 8. Place the module on a work bench, with the vinyl trim cover facing up and away from the surface. 9. Clear a space on the ground about 1.85 M (6 ft) in diameter for deployment of the module. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Verify that you have sufficient ventilation. 10. Clear all loose or flammable objects from the area. 11. Place J 39401-B in the center of the cleared area. 12. Fill the fixture plastic reservoir with water or sand. IMPORTANT: Securely hand tighten all fasteners prior to deployment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10052 13. Mount the module (1) in J39401-B (3) with the vinyl trim cover facing up. 14. To mount, use two M6 x 1.0 nuts (2) with washers in order to secure the module (1) to the deployment fixture (3). 15. Extend the SIR deployment harness and adapter to full length from the module. 16. Place a 12-V minimum, 2-A minimum power source (e.g., vehicle battery) near the shorted end of the harness. 17. Connect the module (1) to the adapter (2) on the SIR deployment harness (3). 18. Firmly seat the adapter into the module connector. 19. Clear the area of people. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10053 20. Separate the two banana plugs on the SIR deployment harness. IMPORTANT ^ The rapid gas expansion involved with deploying an air bag is very loud. Notify all the people in the immediate area that you intend to deploy the inflator module. ^ When the air bag deploys, the SIR deployment fixture may jump vertically. This is a normal reaction of the inflator module to the force of the rapid gas expansion inside the air bag. 21. Connect the SIR deployment harness wires to the power source. 22. Disconnect the SIR deployment harness from the power source after the air bag deploys. 23. Seat one banana plug into the other in order to short the deployment harness leads. 24. If the air bag did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps. CAUTION: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10054 ^ Allow sufficient time for cooling before touching any metal surface of the inflator module. ^ Do not place the deployed inflator module near any flammable objects. 25. Put on a pair of shop gloves. 26. Disconnect the pigtail adapter from the inflator module as soon as possible. 27. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed. 28. Dispose of the deployed module through normal refuse channels. 29. Wash hands with a mild soap. Side Air Bags (Vehicle Scrapping Procedure) You may deploy the inflator modules inside the vehicle prior to destroying the vehicle or when salvaging the vehicle for parts. This includes but is not limited to the following situations: ^ The vehicle has completed its useful life. ^ Irreparable damage has occurred to the vehicle in a non-deployment type accident. ^ Irreparable damage has occurred to the vehicle during a theft. ^ The vehicle is being salvaged for parts to be used on a vehicle with a different VIN, as opposed to rebuilding the vehicle as the same VIN. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed Failure to follow the procedures in the order listed may result in personal injury. 1. Turn the ignition switch to the OFF position. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove all loose objects from the front seats. 5. Disconnect the inflatable restraint front side impact module (LH) yellow 2-way connector located under the driver seat. 6. Cut the yellow 2-way harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 7. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10055 8. Cut two 4.6-M (15-ft) deployment wires from a multi-strand wire 0.8 sq.mm (18 gage) or thicker. Use these wires to fabricate the driver deployment harness. 9. Strip 13 mm (0.5 in) of insulation from both ends of these wires. 10. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the air bag. 11. Twist together one connector wire lead to one deployment wire. 12. Inspect that the previous connection is secure. 13. Bend flat the twisted connection. 14. Secure and insulate the connection using electrical tape. 15. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 16. Connect the deployment harness to the inflatable restraint front side impact module (LH) yellow 2-way connector. 17. Route the deployment harness out of the vehicle's driver side. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10056 18. Disconnect the inflatable restraint front side impact module (RH) yellow 2-way harness connector located under the front passenger seat. 19. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 20. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 21. Cut two 4.6-M (15-ft) deployment wires from a multi-strand wire 0.8 sq.mm (18 gage) or thicker. These wires will be used to fabricate the passenger deployment harness. 22. Strip 13 mm (0.5 in) of insulation from both ends of these wires. 23. Twist together one end from each of the wires in order to short the wires. 24. Twist together one connector wire lead to one deployment wire. 25. Bend flat the twisted connection. 26. Secure and insulate the connection using electrical tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10057 27. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 28. Connect the deployment harness to the inflatable restraint front side impact module (RH) yellow 2-way connector. 29. Route the deployment harness out of the passenger side of the vehicle. 30. Clear the inside and outside of the vehicle of any people or loose and flammable objects. 31. Stretch the driver harness to full length. 32. Stretch the passenger harness to full length. 33. Completely cover the windshield and front door window openings with a drop cloth. 34. Place a power source, 12 V minimum, 2 A minimum (e.g., a vehicle battery) near the shorted end of the harness. 35. Separate the two ends of the driver side air bag deployment harness wires. 36. Connect the driver side air bag deployment harness wires to the power source in order to deploy the inflatable restraint front side impact module (LH). 37. Disconnect the driver side air bag deployment harness wires from the power source. 38. Separate the two ends of the passenger side air bag deployment harness wires. 39. Connect the passenger side air bag deployment harness wires to the power source in order to deploy the inflatable restraint front side impact (RH) module. 40. Disconnect the passenger side air bag deployment harness wires from the power source. 41. Twist together one end of each wire on the driver side air bag deployment harness in order to short the wires. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10058 42. Twist together one end of each wire on the passenger side air bag deployment harness in order to short the wires. 43. Remove the drop cloth from the vehicle. 44. Disconnect both harnesses from the vehicle. 45. Discard the harnesses. 46. Scrap the vehicle in the same manner as a non-SIR equipped vehicle. 47. If one or both of the modules did not deploy, perform the following steps: 47.1. Remove the undeployed modules from the vehicle. 47.2. Temporarily store the modules. 47.3. Call the Technical Assistance Group for further assistance. Frontal Air Bags (Vehicle Scrapping Procedure) You may deploy the inflator modules inside the vehicle prior to destroying the vehicle or when salvaging the vehicle for parts. This includes but is not limited to the following situations: ^ The vehicle has completed its useful life. ^ Irreparable damage has occurred to the vehicle in a non-deployment type accident. ^ Irreparable damage has occurred to the vehicle during a theft. ^ The vehicle is being salvaged for parts to be used on a vehicle with a different VIN, as opposed to rebuilding the vehicle as the same VIN. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. 1. Turn the ignition switch to the OFF position. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove all loose objects from the front seats. 5. Disconnect the inflatable restraint steering wheel module yellow 2-way connector. 6. Cut the yellow 2-way harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 7. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 8. Cut two 4.6-M (15-ft) deployment wires from a multi-strand wire 0.8 sq. mm (18 gage) or thicker. Use these wires to fabricate the driver frontal air bag deployment harness. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10059 9. Strip 13 mm (0.5 in) of insulation from both ends of these wires. 10. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the air bag. 11. Twist together one connector wire lead to one deployment wire. 12. Inspect that the previous connection is secure. 13. Bend flat the twisted connection. 14. Secure and insulate the connection using electrical tape. 15. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 16. Connect the deployment harness to the inflatable restraint steering wheel module yellow 2-way connector. 17. Route the deployment harness out of the vehicle's driver side. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10060 18. Disconnect the inflatable restraint IP module yellow 2-way harness connector. 19. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 20. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 21. Cut two 6.1-M (20-ft) deployment wires from a multi-strand wire 0.8 sq.mm (18 gage) or thicker. These wires will be used to fabricate the passenger deployment harness. 22. Strip 13 mm (0.5 in) of insulation from both ends of these wires. 23. Twist together one end from each of the wires in order to short the wires. 24. Twist together one connector wire lead to one deployment wire. 25. Bend flat the twisted connection. 26. Secure and insulate the connection using electrical tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10061 27. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 28. Connect the deployment harness to the inflatable restraint IP module yellow 2-way connector. 29. Route the deployment harness out of the passenger side of the vehicle. 30. Clear the inside and outside of the vehicle of any people or loose and flammable objects. 31. Stretch the driver harness to full length. 32. Stretch the passenger harness to full length. 33. Completely cover the windshield and front door window openings with a drop cloth. 34. Place a power source, 12 V minimum, 2 A minimum (e.g., a vehicle battery) near the shorted end of the harness. 35. Separate the two ends of the driver frontal air bag deployment harness wires. 36. Connect the driver frontal air bag deployment harness wires to the power source in order to deploy the inflatable restraint steering wheel module. 37. Disconnect the driver frontal air bag deployment harness wires from the power source. 38. Separate the two ends of the passenger frontal air bag deployment harness wires. 39. Connect the passenger frontal air bag deployment harness wires to the power source in order to deploy the inflatable restraint IP module. 40. Disconnect the passenger frontal air bag deployment harness wires from the power source. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10062 41. Twist together one end of each wire on the driver frontal air bag deployment harness in order to short the wires. 42. Twist together one end of each wire on the passenger frontal air bag deployment harness in order to short the wires. 43. Remove the drop cloth from the vehicle. 44. Disconnect both harnesses from the vehicle. 45. Discard the harnesses. 46. Scrap the vehicle in the same manner as a non-SIR equipped vehicle. 47. If one or both of the modules did not deploy, perform the following steps: 47.1. Remove the undeployed modules from the vehicle. 47.2. Temporarily store the modules. 47.3. Call the Technical Assistance Group for further assistance. Handling A Deployed Steering Wheel Inflator Module After the inflator module has deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates), and by-products of the chemical reaction. The deployment reaction produces sodium hydroxide dust (similar to lye soap). The sodium hydroxide quickly reacts with the atmospheric moisture. This atmospheric moisture converts the sodium hydroxide into sodium carbonate and sodium bicarbonate (baking soda). Therefore, you will probably find no sodium hydroxide present after the deployment. Gloves and safety glasses are recommended, however, as a precaution. Gloves and safety glasses help to prevent possible irritation of the skin or eyes. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10063 Air Bag: Service and Repair Inflatable Restraint Instrument Panel Module Replacement CAUTION: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module ^ Make sure the bag opening points away from you When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the instrument panel upper trim pad. 3. Remove the Connector Position Assurance (CPA) from the inflatable restraint IP module yellow 2-way wiring harness connector. 4. Disconnect the inflatable restraint IP module yellow 2-way wiring harness connector. 5. Remove the inflatable restraint IP module mounting fasteners (3). 6. Remove the inflatable restraint IP module (1) from the cross-car beam (2). INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10064 1. Install the inflatable restraint IP module (1) to the cross-car beam (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the inflatable restraint IP module mounting fasteners (3). Tighten Tighten fasteners to 10 N.m (89 lb in). 3. Connect the inflatable restraint IP module yellow 2-way wiring harness connector. 4. Install the CPA to the inflatable restraint IP module yellow 2-way wiring harness connector. 5. Install the instrument panel upper trim pad. 6. Enable the SIR system. Refer to Enabling the SIR System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10065 Air Bag: Service and Repair Handling a Deployed Steering Wheel Inflator Module After the inflator module has deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates), and by-products of the chemical reaction. The deployment reaction produces sodium hydroxide dust (similar to lye soap). The sodium hydroxide quickly reacts with the atmospheric moisture. This atmospheric moisture converts the sodium hydroxide into sodium carbonate and sodium bicarbonate (baking soda). Therefore, you will probably find no sodium hydroxide present after the deployment. Gloves and safety glasses are recommended, however, as a precaution. Gloves and safety glasses help to prevent possible irritation of the skin or eyes. Inflator Module Handling, Shipping, and Scrapping LIVE (UNDEPLOYED) INFLATOR MODULE CAUTION: Refer to Inflator Module Handling And Storage Caution in Service Precautions. Be careful when you handle or store a live (undeployed) inflator module. An air bag deployment produces rapid gas generation. This may cause the inflator module or an object in front of the inflator module to jettison through the air in the event of an unlikely deployment. SHIPPING PROCEDURES Refer to the latest service bulletins for proper SIR inflator module shipping procedures. SCRAPPING PROCEDURE During the course of a vehicle's useful life, certain situations may arise which will require the disposal of a live (undeployed) inflator module. The following information covers the proper procedures for this disposal. Deploy the inflator module before disposal. Do not dispose the module through normal disposal channels. CAUTION: Refer to Inflator Module Disposal Caution in Service Precautions. Do NOT deploy an air bag in the following situations: ^ After replacing an inflator module under warranty, the module may need to be returned undeployed to the original manufacturer. Refer to the latest service bulletin regarding SIR shipping procedures. ^ If the vehicle is the subject of a Product Liability report related to the SIR system and is subject to a Preliminary Investigation (GM-1241), do not alter the SIR system in any manner. Refer to the latest service bulletin on SIR shipping procedures. ^ If the vehicle is involved in a campaign affecting the inflator modules, follow the instructions in the Campaign Service Bulletin for proper SIR handling and shipping procedures. General Information You may deploy the inflator module inside or outside of the vehicle. The method used depends upon the final disposition of the vehicle. Review the following procedures in order to determine which will work best in a given situation Inflatable Restraint Steering Wheel Module TOOLS REQUIRED ^ J 38826 SIR Deployment Harness ^ An appropriate pigtail adapter CAUTION ^ Refer to Inflator Module Disposal Caution in Service Precautions. ^ When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Deploy the inflatable restraint steering wheel module outside of the vehicle when the vehicle will be returned to service. Situations that require Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10066 deployment outside of the vehicle include the following: ^ Using the SIR diagnostics, you determine that the inflator module does not function properly. ^ The inflator module is scratched or ripped on the cover. ^ The inflator module pigtail harness is damaged. ^ The inflator module connector is damaged. ^ An inflator module connector terminal is damaged. Deployment and disposal of a malfunctioning inflator module is subject to any required retention period. 1. Turn OFF the ignition. 2. Remove the key from the ignition switch. 3. Put on safety glasses. 4. Inspect J 38826 and the appropriate pigtail adaptor for damage. Replace as needed. 5. Short the two SIR deployment harness (1) leads together using one banana plug seated into the other. 6. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). 7. Remove the inflatable restraint steering wheel module from the vehicle. CAUTION: Refer to Inflator Module Handling And Storage Caution in Service Precautions. 8. Place the module on a work bench, with the vinyl trim cover facing up and away from the surface. 9. Clear a space on the ground about 1.85 M (6 ft) in diameter for deployment of the module. If possible, use a paved, outdoor location free of Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10067 activity. Otherwise use a space free of activity on the shop floor. Verify that you have sufficient ventilation. 10. Clear all loose or flammable objects from the area. 11. Place the module in the center of the space with the vinyl trim cover facing up. 12. Extend the SIR deployment harness and adapter to full length from the module. 13. Place a 12-V minimum, 2-A minimum power source (e.g., a vehicle battery) near the shorted end of the harness. 14. Connect the module (1) to the adapter (2) on the SIR deployment harness (3). 15. Firmly seat the adapter into the module connector. 16. Clear the area of people. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. 17. Separate the two banana plugs on the SIR deployment harness. IMPORTANT ^ The rapid gas expansion involved with deploying an air bag is very loud. Notify all people in the immediate area that you intend to deploy the inflator module. ^ When the air bag deploys, the inflator module may jump about 30 cm (1 ft) vertically. This is a normal reaction of the inflator module to the force of the rapid gas expansion inside the air bag. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10068 18. Connect the SIR deployment harness wires to the power source. 19. Disconnect the SIR deployment harness from the power source after the air bag deploys. 20. Seat one banana plug into the other in order to short the deployment harness leads. 21. If the air bag did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, continue performing the following steps. CAUTION: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury: ^ Allow sufficient time for cooling before touching any metal surface of the inflator module. ^ Do not place the deployed inflator module near any flammable objects. 22. Put on a pair of shop gloves. 23. Disconnect the pigtail adapter from the inflator module as soon as possible. 24. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed. 25. Dispose of the deployed module through normal refuse channels. 26. Wash your hands with a mild soap. Inflatable Restraint I/P Module TOOLS REQUIRED ^ J 39401-B Sir Deployment Fixture ^ J 38826 Sir Deployment Harness ^ An appropriate pigtail adapter CAUTION Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10069 ^ Refer to Inflator Module Disposal Caution in Service Precautions. ^ When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Deploy the inflatable restraint instrument panel inflator module outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: ^ Using the SIR diagnostics, you determine that the inflator module does not function properly. ^ The inflator module is scratched or ripped on the cover. ^ The inflator module pigtail (if equipped) is damaged. ^ The inflator module connector is damaged. ^ An inflator module connector terminal is damaged. Deployment and disposal of a malfunctioning inflator module is subject to any required retention period. IMPORTANT: Refer to the latest General Motors Service Bulletins before deploying a passenger inflator module. 1. Turn OFF the ignition. 2. Remove the key from the ignition switch. 3. Put on safety glasses. 4. Inspect J 38826 and the appropriate pigtail adapter for damage. Replace as needed. 5. Short the two SIR deployment harness (1) leads together using one banana plug seated into the other. 6. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). 7. Remove the inflatable restraint instrument panel module. CAUTION: Refer to Inflator Module Handling And Storage Caution in Service Precautions. 8. Place the module on a work bench, with the vinyl trim cover facing up and away from the surface. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10070 9. Clear a space on the ground about 1.85 M (6 ft) in diameter for deployment of the module. If possible, use a paved, outdoor location free of activity. Otherwise use a space free of activity on the shop floor. Verify that you have sufficient ventilation. 10. Clear all loose or flammable objects from the area. 11. Place J 39401-B in the center of the cleared area. 12. Fill the fixture plastic reservoir with water or sand. IMPORTANT: Securely hand tighten all fasteners prior to deployment. 13. Secure the J 39401-7A arms (5) to J39401-B (2) using carriage bolts (3) and nuts (4). 14. Mount the module (1) in J39401-B with the vinyl trim cover facing up. 15. To mount, use four M6 bolts (6), nuts (8), and washers (7) in order to secure the module (1) to the deployment fixture (2). 16. Extend the SIR deployment harness and adapter to full length from the module. 17. Place a 12-V minimum, 2-A minimum power source (e.g., a vehicle battery) near the shorted end of the harness. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10071 18. Connect the module (1) to the adapter (2) on the SIR deployment harness (3). 19. Firmly seat the adapter into the module connector. 20. Clear the area of people. CAUTION: When you are deploying an inflator module for disposal perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. 21. Separate the two banana plugs on the SIR deployment harness. IMPORTANT ^ The rapid gas expansion involved with deploying an air bag is very loud. Notify all the people in the immediate area that you intend to deploy the inflator module. ^ When the air bag deploys, the SIR deployment fixture may jump vertically. This is a normal reaction of the inflator module to the force of the rapid gas expansion inside the air bag. 22. Connect the SIR deployment harness wires to the power source. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10072 23. Disconnect the SIR deployment harness from the power source after the air bag deploys. 24. Seat one banana plug into the other in order to short the deployment harness leads. 25. If the air bag did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps. CAUTION: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury: ^ Allow sufficient time for cooling before touching any metal surfaces of the inflator module. ^ Do not place the deployed inflator module near any flammable objects. 26. Put on a pair of shop gloves. 27. Disconnect the pigtail adapter from the inflator module as soon as possible. 28. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed. 29. Dispose of the deployed module through normal refuse channels. 30. Wash your hands with a mild soap. Inflatable Restraint Side Impact Module TOOLS REQUIRED ^ J 39401-B SIR Deployment Fixture ^ J 38826 SIR Deployment Harness ^ An appropriate pigtail adapter CAUTION ^ Refer to inflator Module Disposal Caution in Service Precautions. ^ When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Deploy the inflatable restraint side impact inflator module outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: ^ Using the SIR diagnostics, you determine that the inflator module does not function properly. ^ The inflator module is scratched or ripped on the cover. ^ The inflator module pigtail (if equipped) is damaged. ^ The inflator module connector is damaged. ^ An inflator module connector terminal is damaged. Deployment and disposal of a malfunctioning inflator module is subject to any required retention period. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10073 IMPORTANT: Refer to the latest General Motors Service Bulletins before deploying a side impact inflator module. 1. Turn OFF the ignition. 2. Remove the key from the ignition switch. 3. Put on safety glasses. 4. Inspect J 38826 and the appropriate pigtail adapter for damage. Replace as needed. 5. Short the two SIR deployment harness (1) leads together using one banana plug seated into the other. 6. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). 7. Remove the inflatable restraint side impact module. CAUTION: Refer to Inflator Module Handling And Storage Caution in Service Precautions. 8. Place the module on a work bench, with the vinyl trim cover facing up and away from the surface. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10074 9. Clear a space on the ground about 1.85 M (6 ft) in diameter for deployment of the module. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Verify that you have sufficient ventilation. 10. Clear all loose or flammable objects from the area. 11. Place J 39401-B in the center of the cleared area. 12. Fill the fixture plastic reservoir with water or sand. IMPORTANT: Securely hand tighten all fasteners prior to deployment. 13. Mount the module (1) in J39401-B (3) with the vinyl trim cover facing up. 14. To mount, use two M6 x 1.0 nuts (2) with washers in order to secure the module (1) to the deployment fixture (3). 15. Extend the SIR deployment harness and adapter to full length from the module. 16. Place a 12-V minimum, 2-A minimum power source (e.g., vehicle battery) near the shorted end of the harness. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10075 17. Connect the module (1) to the adapter (2) on the SIR deployment harness (3). 18. Firmly seat the adapter into the module connector. 19. Clear the area of people. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. 20. Separate the two banana plugs on the SIR deployment harness. IMPORTANT ^ The rapid gas expansion involved with deploying an air bag is very loud. Notify all the people in the immediate area that you intend to deploy the inflator module. ^ When the air bag deploys, the SIR deployment fixture may jump vertically. This is a normal reaction of the inflator module to the force of the rapid gas expansion inside the air bag. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10076 21. Connect the SIR deployment harness wires to the power source. 22. Disconnect the SIR deployment harness from the power source after the air bag deploys. 23. Seat one banana plug into the other in order to short the deployment harness leads. 24. If the air bag did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps. CAUTION: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury: ^ Allow sufficient time for cooling before touching any metal surface of the inflator module. ^ Do not place the deployed inflator module near any flammable objects. 25. Put on a pair of shop gloves. 26. Disconnect the pigtail adapter from the inflator module as soon as possible. 27. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed. 28. Dispose of the deployed module through normal refuse channels. 29. Wash hands with a mild soap. Side Air Bags (Vehicle Scrapping Procedure) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10077 You may deploy the inflator modules inside the vehicle prior to destroying the vehicle or when salvaging the vehicle for parts. This includes but is not limited to the following situations: ^ The vehicle has completed its useful life. ^ Irreparable damage has occurred to the vehicle in a non-deployment type accident. ^ Irreparable damage has occurred to the vehicle during a theft. ^ The vehicle is being salvaged for parts to be used on a vehicle with a different VIN, as opposed to rebuilding the vehicle as the same VIN. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed Failure to follow the procedures in the order listed may result in personal injury. 1. Turn the ignition switch to the OFF position. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove all loose objects from the front seats. 5. Disconnect the inflatable restraint front side impact module (LH) yellow 2-way connector located under the driver seat. 6. Cut the yellow 2-way harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 7. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 8. Cut two 4.6-M (15-ft) deployment wires from a multi-strand wire 0.8 sq.mm (18 gage) or thicker. Use these wires to fabricate the driver deployment harness. 9. Strip 13 mm (0.5 in) of insulation from both ends of these wires. 10. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the air bag. 11. Twist together one connector wire lead to one deployment wire. 12. Inspect that the previous connection is secure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10078 13. Bend flat the twisted connection. 14. Secure and insulate the connection using electrical tape. 15. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 16. Connect the deployment harness to the inflatable restraint front side impact module (LH) yellow 2-way connector. 17. Route the deployment harness out of the vehicle's driver side. 18. Disconnect the inflatable restraint front side impact module (RH) yellow 2-way harness connector located under the front passenger seat. 19. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 20. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10079 21. Cut two 4.6-M (15-ft) deployment wires from a multi-strand wire 0.8 sq.mm (18 gage) or thicker. These wires will be used to fabricate the passenger deployment harness. 22. Strip 13 mm (0.5 in) of insulation from both ends of these wires. 23. Twist together one end from each of the wires in order to short the wires. 24. Twist together one connector wire lead to one deployment wire. 25. Bend flat the twisted connection. 26. Secure and insulate the connection using electrical tape. 27. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 28. Connect the deployment harness to the inflatable restraint front side impact module (RH) yellow 2-way connector. 29. Route the deployment harness out of the passenger side of the vehicle. 30. Clear the inside and outside of the vehicle of any people or loose and flammable objects. 31. Stretch the driver harness to full length. 32. Stretch the passenger harness to full length. 33. Completely cover the windshield and front door window openings with a drop cloth. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10080 34. Place a power source, 12 V minimum, 2 A minimum (e.g., a vehicle battery) near the shorted end of the harness. 35. Separate the two ends of the driver side air bag deployment harness wires. 36. Connect the driver side air bag deployment harness wires to the power source in order to deploy the inflatable restraint front side impact module (LH). 37. Disconnect the driver side air bag deployment harness wires from the power source. 38. Separate the two ends of the passenger side air bag deployment harness wires. 39. Connect the passenger side air bag deployment harness wires to the power source in order to deploy the inflatable restraint front side impact (RH) module. 40. Disconnect the passenger side air bag deployment harness wires from the power source. 41. Twist together one end of each wire on the driver side air bag deployment harness in order to short the wires. 42. Twist together one end of each wire on the passenger side air bag deployment harness in order to short the wires. 43. Remove the drop cloth from the vehicle. 44. Disconnect both harnesses from the vehicle. 45. Discard the harnesses. 46. Scrap the vehicle in the same manner as a non-SIR equipped vehicle. 47. If one or both of the modules did not deploy, perform the following steps: 47.1. Remove the undeployed modules from the vehicle. 47.2. Temporarily store the modules. 47.3. Call the Technical Assistance Group for further assistance. Frontal Air Bags (Vehicle Scrapping Procedure) You may deploy the inflator modules inside the vehicle prior to destroying the vehicle or when salvaging the vehicle for parts. This includes but is not limited to the following situations: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10081 ^ The vehicle has completed its useful life. ^ Irreparable damage has occurred to the vehicle in a non-deployment type accident. ^ Irreparable damage has occurred to the vehicle during a theft. ^ The vehicle is being salvaged for parts to be used on a vehicle with a different VIN, as opposed to rebuilding the vehicle as the same VIN. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. 1. Turn the ignition switch to the OFF position. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove all loose objects from the front seats. 5. Disconnect the inflatable restraint steering wheel module yellow 2-way connector. 6. Cut the yellow 2-way harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 7. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 8. Cut two 4.6-M (15-ft) deployment wires from a multi-strand wire 0.8 sq. mm (18 gage) or thicker. Use these wires to fabricate the driver frontal air bag deployment harness. 9. Strip 13 mm (0.5 in) of insulation from both ends of these wires. 10. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the air bag. 11. Twist together one connector wire lead to one deployment wire. 12. Inspect that the previous connection is secure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10082 13. Bend flat the twisted connection. 14. Secure and insulate the connection using electrical tape. 15. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 16. Connect the deployment harness to the inflatable restraint steering wheel module yellow 2-way connector. 17. Route the deployment harness out of the vehicle's driver side. 18. Disconnect the inflatable restraint IP module yellow 2-way harness connector. 19. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 20. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10083 21. Cut two 6.1-M (20-ft) deployment wires from a multi-strand wire 0.8 sq.mm (18 gage) or thicker. These wires will be used to fabricate the passenger deployment harness. 22. Strip 13 mm (0.5 in) of insulation from both ends of these wires. 23. Twist together one end from each of the wires in order to short the wires. 24. Twist together one connector wire lead to one deployment wire. 25. Bend flat the twisted connection. 26. Secure and insulate the connection using electrical tape. 27. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 28. Connect the deployment harness to the inflatable restraint IP module yellow 2-way connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10084 29. Route the deployment harness out of the passenger side of the vehicle. 30. Clear the inside and outside of the vehicle of any people or loose and flammable objects. 31. Stretch the driver harness to full length. 32. Stretch the passenger harness to full length. 33. Completely cover the windshield and front door window openings with a drop cloth. 34. Place a power source, 12 V minimum, 2 A minimum (e.g., a vehicle battery) near the shorted end of the harness. 35. Separate the two ends of the driver frontal air bag deployment harness wires. 36. Connect the driver frontal air bag deployment harness wires to the power source in order to deploy the inflatable restraint steering wheel module. 37. Disconnect the driver frontal air bag deployment harness wires from the power source. 38. Separate the two ends of the passenger frontal air bag deployment harness wires. 39. Connect the passenger frontal air bag deployment harness wires to the power source in order to deploy the inflatable restraint IP module. 40. Disconnect the passenger frontal air bag deployment harness wires from the power source. 41. Twist together one end of each wire on the driver frontal air bag deployment harness in order to short the wires. 42. Twist together one end of each wire on the passenger frontal air bag deployment harness in order to short the wires. 43. Remove the drop cloth from the vehicle. 44. Disconnect both harnesses from the vehicle. 45. Discard the harnesses. 46. Scrap the vehicle in the same manner as a non-SIR equipped vehicle. 47. If one or both of the modules did not deploy, perform the following steps: 47.1. Remove the undeployed modules from the vehicle. 47.2. Temporarily store the modules. 47.3. Call the Technical Assistance Group for further assistance. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10085 Inflatable Restraint Instrument Panel Module Replacement CAUTION: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module ^ Make sure the bag opening points away from you When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the instrument panel upper trim pad. 3. Remove the Connector Position Assurance (CPA) from the inflatable restraint IP module yellow 2-way wiring harness connector. 4. Disconnect the inflatable restraint IP module yellow 2-way wiring harness connector. 5. Remove the inflatable restraint IP module mounting fasteners (3). 6. Remove the inflatable restraint IP module (1) from the cross-car beam (2). INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10086 1. Install the inflatable restraint IP module (1) to the cross-car beam (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the inflatable restraint IP module mounting fasteners (3). Tighten Tighten fasteners to 10 N.m (89 lb in). 3. Connect the inflatable restraint IP module yellow 2-way wiring harness connector. 4. Install the CPA to the inflatable restraint IP module yellow 2-way wiring harness connector. 5. Install the instrument panel upper trim pad. 6. Enable the SIR system. Refer to Enabling the SIR System. Inflatable Restraint Steering Wheel Module Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10087 2. Insert a flat-bladed screwdriver into one of the four openings in the back of the steering wheel. 3. Turn the screwdriver counterclockwise to disengage the spring from the slot in the module. 4. Pull the module gently away from the steering wheel. 5. Repeat the previous three steps for the remaining openings. 6. Remove the inflator module from the steering wheel. 7. Remove the Connector Position Assurance (CPA) from the driver frontal air bag electrical connector. 8. Disconnect the electrical connector from the back of the module. 9. Rotate the horn contact lead counterclockwise 1/4 turn in order to remove the horn contact lead from the steering column cam tower. INSTALLATION PROCEDURE 1. Install the horn contact lead to the steering column cam tower. 2. Connect the electrical connector to the back of the module. 3. Install the CPA to the module electrical connector. 4. Install the module to the steering wheel by pushing on both the right and left sides of the inflator module until the retaining springs engage. 5. Enable the SIR system. Refer to Enabling the SIR System. Inflatable Restraint Side Impact Module Replacement - Front REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the driver seat. 3. Unclip the J-clip that is along the lower rear seat back. 4. Remove the seat back cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10088 5. Remove the driver side air bag fasteners (2). 6. Note the routing of the driver side air bag wiring harness (4) and retaining clip attachments within the driver seat. 7. Remove the driver side air bag wiring harness (4) retaining clips from the driver seat frame. 8. Gently pull the pigtail harness up into the seat back while guiding the harness through the wire triangle of the seat frame. 9. Remove the module (1) from the driver seat back frame. INSTALLATION PROCEDURE 1. Install the module (1) to the seat while guiding the pigtail harness through the trim cup. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the driver side air fasteners (2). Tighten Tighten the driver side air bag fasteners to 10 N.m (89 lb in). 3. Gently pull the driver side air bag wiring harness (4) down into the seat cushion while guiding the harness through the wire triangle of the seat frame. 4. Install the harness retaining clips to the seat frame. 5. Install the seat back cover. 6. Connect together the J-clip that is along the lower rear seat back. 7. Install the driver seat. 8. Enable the SIR system. Refer to Enabling the SIR System. Inflator Module Handling, Shipping, and Scrapping LIVE (UNDEPLOYED) INFLATOR MODULE CAUTION: Refer to Inflator Module Handling And Storage Caution in Service Precautions. Be careful when you handle or store a live (undeployed) inflator module. An air bag deployment produces rapid gas generation. This may cause the inflator module or an object in front of the inflator module to jettison through the air in the event of an unlikely deployment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10089 SHIPPING PROCEDURES Refer to the latest service bulletins for proper SIR inflator module shipping procedures. SCRAPPING PROCEDURE During the course of a vehicle's useful life, certain situations may arise which will require the disposal of a live (undeployed) inflator module. The following information covers the proper procedures for this disposal. Deploy the inflator module before disposal. Do not dispose the module through normal disposal channels. CAUTION: Refer to Inflator Module Disposal Caution in Service Precautions. Do NOT deploy an air bag in the following situations: ^ After replacing an inflator module under warranty, the module may need to be returned undeployed to the original manufacturer. Refer to the latest service bulletin regarding SIR shipping procedures. ^ If the vehicle is the subject of a Product Liability report related to the SIR system and is subject to a Preliminary Investigation (GM-1241), do not alter the SIR system in any manner. Refer to the latest service bulletin on SIR shipping procedures. ^ If the vehicle is involved in a campaign affecting the inflator modules, follow the instructions in the Campaign Service Bulletin for proper SIR handling and shipping procedures. General Information You may deploy the inflator module inside or outside of the vehicle. The method used depends upon the final disposition of the vehicle. Review the following procedures in order to determine which will work best in a given situation Inflatable Restraint Steering Wheel Module TOOLS REQUIRED ^ J 38826 SIR Deployment Harness ^ An appropriate pigtail adapter CAUTION ^ Refer to Inflator Module Disposal Caution in Service Precautions. ^ When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Deploy the inflatable restraint steering wheel module outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: ^ Using the SIR diagnostics, you determine that the inflator module does not function properly. ^ The inflator module is scratched or ripped on the cover. ^ The inflator module pigtail harness is damaged. ^ The inflator module connector is damaged. ^ An inflator module connector terminal is damaged. Deployment and disposal of a malfunctioning inflator module is subject to any required retention period. 1. Turn OFF the ignition. 2. Remove the key from the ignition switch. 3. Put on safety glasses. 4. Inspect J 38826 and the appropriate pigtail adaptor for damage. Replace as needed. 5. Short the two SIR deployment harness (1) leads together using one banana plug seated into the other. 6. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10090 7. Remove the inflatable restraint steering wheel module from the vehicle. CAUTION: Refer to Inflator Module Handling And Storage Caution in Service Precautions. 8. Place the module on a work bench, with the vinyl trim cover facing up and away from the surface. 9. Clear a space on the ground about 1.85 M (6 ft) in diameter for deployment of the module. If possible, use a paved, outdoor location free of activity. Otherwise use a space free of activity on the shop floor. Verify that you have sufficient ventilation. 10. Clear all loose or flammable objects from the area. 11. Place the module in the center of the space with the vinyl trim cover facing up. 12. Extend the SIR deployment harness and adapter to full length from the module. 13. Place a 12-V minimum, 2-A minimum power source (e.g., a vehicle battery) near the shorted end of the harness. 14. Connect the module (1) to the adapter (2) on the SIR deployment harness (3). 15. Firmly seat the adapter into the module connector. 16. Clear the area of people. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10091 CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. 17. Separate the two banana plugs on the SIR deployment harness. IMPORTANT ^ The rapid gas expansion involved with deploying an air bag is very loud. Notify all people in the immediate area that you intend to deploy the inflator module. ^ When the air bag deploys, the inflator module may jump about 30 cm (1 ft) vertically. This is a normal reaction of the inflator module to the force of the rapid gas expansion inside the air bag. 18. Connect the SIR deployment harness wires to the power source. 19. Disconnect the SIR deployment harness from the power source after the air bag deploys. 20. Seat one banana plug into the other in order to short the deployment harness leads. 21. If the air bag did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, continue performing the following steps. CAUTION: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury: ^ Allow sufficient time for cooling before touching any metal surface of the inflator module. ^ Do not place the deployed inflator module near any flammable objects. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10092 22. Put on a pair of shop gloves. 23. Disconnect the pigtail adapter from the inflator module as soon as possible. 24. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed. 25. Dispose of the deployed module through normal refuse channels. 26. Wash your hands with a mild soap. Inflatable Restraint IP Module TOOLS REQUIRED ^ J 39401-B Sir Deployment Fixture ^ J 38826 Sir Deployment Harness ^ An appropriate pigtail adapter CAUTION ^ Refer to Inflator Module Disposal Caution in Service Precautions. ^ When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Deploy the inflatable restraint instrument panel inflator module outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: ^ Using the SIR diagnostics, you determine that the inflator module does not function properly. ^ The inflator module is scratched or ripped on the cover. ^ The inflator module pigtail (if equipped) is damaged. ^ The inflator module connector is damaged. ^ An inflator module connector terminal is damaged. Deployment and disposal of a malfunctioning inflator module is subject to any required retention period. IMPORTANT: Refer to the latest General Motors Service Bulletins before deploying a passenger inflator module. 1. Turn OFF the ignition. 2. Remove the key from the ignition switch. 3. Put on safety glasses. 4. Inspect J 38826 and the appropriate pigtail adapter for damage. Replace as needed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10093 5. Short the two SIR deployment harness (1) leads together using one banana plug seated into the other. 6. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). 7. Remove the inflatable restraint instrument panel module. CAUTION: Refer to Inflator Module Handling And Storage Caution in Service Precautions. 8. Place the module on a work bench, with the vinyl trim cover facing up and away from the surface. 9. Clear a space on the ground about 1.85 M (6 ft) in diameter for deployment of the module. If possible, use a paved, outdoor location free of activity. Otherwise use a space free of activity on the shop floor. Verify that you have sufficient ventilation. 10. Clear all loose or flammable objects from the area. 11. Place J 39401-B in the center of the cleared area. 12. Fill the fixture plastic reservoir with water or sand. IMPORTANT: Securely hand tighten all fasteners prior to deployment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10094 13. Secure the J 39401-7A arms (5) to J39401-B (2) using carriage bolts (3) and nuts (4). 14. Mount the module (1) in J39401-B with the vinyl trim cover facing up. 15. To mount, use four M6 bolts (6), nuts (8), and washers (7) in order to secure the module (1) to the deployment fixture (2). 16. Extend the SIR deployment harness and adapter to full length from the module. 17. Place a 12-V minimum, 2-A minimum power source (e.g., a vehicle battery) near the shorted end of the harness. 18. Connect the module (1) to the adapter (2) on the SIR deployment harness (3). 19. Firmly seat the adapter into the module connector. 20. Clear the area of people. CAUTION: When you are deploying an inflator module for disposal perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10095 21. Separate the two banana plugs on the SIR deployment harness. IMPORTANT ^ The rapid gas expansion involved with deploying an air bag is very loud. Notify all the people in the immediate area that you intend to deploy the inflator module. ^ When the air bag deploys, the SIR deployment fixture may jump vertically. This is a normal reaction of the inflator module to the force of the rapid gas expansion inside the air bag. 22. Connect the SIR deployment harness wires to the power source. 23. Disconnect the SIR deployment harness from the power source after the air bag deploys. 24. Seat one banana plug into the other in order to short the deployment harness leads. 25. If the air bag did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps. CAUTION: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury: ^ Allow sufficient time for cooling before touching any metal surfaces of the inflator module. ^ Do not place the deployed inflator module near any flammable objects. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10096 26. Put on a pair of shop gloves. 27. Disconnect the pigtail adapter from the inflator module as soon as possible. 28. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed. 29. Dispose of the deployed module through normal refuse channels. 30. Wash your hands with a mild soap. Inflatable Restraint Side Impact Module TOOLS REQUIRED ^ J 39401-B SIR Deployment Fixture ^ J 38826 SIR Deployment Harness ^ An appropriate pigtail adapter CAUTION ^ Refer to inflator Module Disposal Caution in Service Precautions. ^ When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Deploy the inflatable restraint side impact inflator module outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: ^ Using the SIR diagnostics, you determine that the inflator module does not function properly. ^ The inflator module is scratched or ripped on the cover. ^ The inflator module pigtail (if equipped) is damaged. ^ The inflator module connector is damaged. ^ An inflator module connector terminal is damaged. Deployment and disposal of a malfunctioning inflator module is subject to any required retention period. IMPORTANT: Refer to the latest General Motors Service Bulletins before deploying a side impact inflator module. 1. Turn OFF the ignition. 2. Remove the key from the ignition switch. 3. Put on safety glasses. 4. Inspect J 38826 and the appropriate pigtail adapter for damage. Replace as needed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10097 5. Short the two SIR deployment harness (1) leads together using one banana plug seated into the other. 6. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). 7. Remove the inflatable restraint side impact module. CAUTION: Refer to Inflator Module Handling And Storage Caution in Service Precautions. 8. Place the module on a work bench, with the vinyl trim cover facing up and away from the surface. 9. Clear a space on the ground about 1.85 M (6 ft) in diameter for deployment of the module. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Verify that you have sufficient ventilation. 10. Clear all loose or flammable objects from the area. 11. Place J 39401-B in the center of the cleared area. 12. Fill the fixture plastic reservoir with water or sand. IMPORTANT: Securely hand tighten all fasteners prior to deployment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10098 13. Mount the module (1) in J39401-B (3) with the vinyl trim cover facing up. 14. To mount, use two M6 x 1.0 nuts (2) with washers in order to secure the module (1) to the deployment fixture (3). 15. Extend the SIR deployment harness and adapter to full length from the module. 16. Place a 12-V minimum, 2-A minimum power source (e.g., vehicle battery) near the shorted end of the harness. 17. Connect the module (1) to the adapter (2) on the SIR deployment harness (3). 18. Firmly seat the adapter into the module connector. 19. Clear the area of people. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10099 20. Separate the two banana plugs on the SIR deployment harness. IMPORTANT ^ The rapid gas expansion involved with deploying an air bag is very loud. Notify all the people in the immediate area that you intend to deploy the inflator module. ^ When the air bag deploys, the SIR deployment fixture may jump vertically. This is a normal reaction of the inflator module to the force of the rapid gas expansion inside the air bag. 21. Connect the SIR deployment harness wires to the power source. 22. Disconnect the SIR deployment harness from the power source after the air bag deploys. 23. Seat one banana plug into the other in order to short the deployment harness leads. 24. If the air bag did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps. CAUTION: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10100 ^ Allow sufficient time for cooling before touching any metal surface of the inflator module. ^ Do not place the deployed inflator module near any flammable objects. 25. Put on a pair of shop gloves. 26. Disconnect the pigtail adapter from the inflator module as soon as possible. 27. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed. 28. Dispose of the deployed module through normal refuse channels. 29. Wash hands with a mild soap. Side Air Bags (Vehicle Scrapping Procedure) You may deploy the inflator modules inside the vehicle prior to destroying the vehicle or when salvaging the vehicle for parts. This includes but is not limited to the following situations: ^ The vehicle has completed its useful life. ^ Irreparable damage has occurred to the vehicle in a non-deployment type accident. ^ Irreparable damage has occurred to the vehicle during a theft. ^ The vehicle is being salvaged for parts to be used on a vehicle with a different VIN, as opposed to rebuilding the vehicle as the same VIN. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed Failure to follow the procedures in the order listed may result in personal injury. 1. Turn the ignition switch to the OFF position. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove all loose objects from the front seats. 5. Disconnect the inflatable restraint front side impact module (LH) yellow 2-way connector located under the driver seat. 6. Cut the yellow 2-way harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 7. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10101 8. Cut two 4.6-M (15-ft) deployment wires from a multi-strand wire 0.8 sq.mm (18 gage) or thicker. Use these wires to fabricate the driver deployment harness. 9. Strip 13 mm (0.5 in) of insulation from both ends of these wires. 10. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the air bag. 11. Twist together one connector wire lead to one deployment wire. 12. Inspect that the previous connection is secure. 13. Bend flat the twisted connection. 14. Secure and insulate the connection using electrical tape. 15. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 16. Connect the deployment harness to the inflatable restraint front side impact module (LH) yellow 2-way connector. 17. Route the deployment harness out of the vehicle's driver side. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10102 18. Disconnect the inflatable restraint front side impact module (RH) yellow 2-way harness connector located under the front passenger seat. 19. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 20. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 21. Cut two 4.6-M (15-ft) deployment wires from a multi-strand wire 0.8 sq.mm (18 gage) or thicker. These wires will be used to fabricate the passenger deployment harness. 22. Strip 13 mm (0.5 in) of insulation from both ends of these wires. 23. Twist together one end from each of the wires in order to short the wires. 24. Twist together one connector wire lead to one deployment wire. 25. Bend flat the twisted connection. 26. Secure and insulate the connection using electrical tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10103 27. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 28. Connect the deployment harness to the inflatable restraint front side impact module (RH) yellow 2-way connector. 29. Route the deployment harness out of the passenger side of the vehicle. 30. Clear the inside and outside of the vehicle of any people or loose and flammable objects. 31. Stretch the driver harness to full length. 32. Stretch the passenger harness to full length. 33. Completely cover the windshield and front door window openings with a drop cloth. 34. Place a power source, 12 V minimum, 2 A minimum (e.g., a vehicle battery) near the shorted end of the harness. 35. Separate the two ends of the driver side air bag deployment harness wires. 36. Connect the driver side air bag deployment harness wires to the power source in order to deploy the inflatable restraint front side impact module (LH). 37. Disconnect the driver side air bag deployment harness wires from the power source. 38. Separate the two ends of the passenger side air bag deployment harness wires. 39. Connect the passenger side air bag deployment harness wires to the power source in order to deploy the inflatable restraint front side impact (RH) module. 40. Disconnect the passenger side air bag deployment harness wires from the power source. 41. Twist together one end of each wire on the driver side air bag deployment harness in order to short the wires. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10104 42. Twist together one end of each wire on the passenger side air bag deployment harness in order to short the wires. 43. Remove the drop cloth from the vehicle. 44. Disconnect both harnesses from the vehicle. 45. Discard the harnesses. 46. Scrap the vehicle in the same manner as a non-SIR equipped vehicle. 47. If one or both of the modules did not deploy, perform the following steps: 47.1. Remove the undeployed modules from the vehicle. 47.2. Temporarily store the modules. 47.3. Call the Technical Assistance Group for further assistance. Frontal Air Bags (Vehicle Scrapping Procedure) You may deploy the inflator modules inside the vehicle prior to destroying the vehicle or when salvaging the vehicle for parts. This includes but is not limited to the following situations: ^ The vehicle has completed its useful life. ^ Irreparable damage has occurred to the vehicle in a non-deployment type accident. ^ Irreparable damage has occurred to the vehicle during a theft. ^ The vehicle is being salvaged for parts to be used on a vehicle with a different VIN, as opposed to rebuilding the vehicle as the same VIN. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. 1. Turn the ignition switch to the OFF position. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove all loose objects from the front seats. 5. Disconnect the inflatable restraint steering wheel module yellow 2-way connector. 6. Cut the yellow 2-way harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 7. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 8. Cut two 4.6-M (15-ft) deployment wires from a multi-strand wire 0.8 sq. mm (18 gage) or thicker. Use these wires to fabricate the driver frontal air bag deployment harness. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10105 9. Strip 13 mm (0.5 in) of insulation from both ends of these wires. 10. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the air bag. 11. Twist together one connector wire lead to one deployment wire. 12. Inspect that the previous connection is secure. 13. Bend flat the twisted connection. 14. Secure and insulate the connection using electrical tape. 15. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 16. Connect the deployment harness to the inflatable restraint steering wheel module yellow 2-way connector. 17. Route the deployment harness out of the vehicle's driver side. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10106 18. Disconnect the inflatable restraint IP module yellow 2-way harness connector. 19. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 20. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 21. Cut two 6.1-M (20-ft) deployment wires from a multi-strand wire 0.8 sq.mm (18 gage) or thicker. These wires will be used to fabricate the passenger deployment harness. 22. Strip 13 mm (0.5 in) of insulation from both ends of these wires. 23. Twist together one end from each of the wires in order to short the wires. 24. Twist together one connector wire lead to one deployment wire. 25. Bend flat the twisted connection. 26. Secure and insulate the connection using electrical tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10107 27. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 28. Connect the deployment harness to the inflatable restraint IP module yellow 2-way connector. 29. Route the deployment harness out of the passenger side of the vehicle. 30. Clear the inside and outside of the vehicle of any people or loose and flammable objects. 31. Stretch the driver harness to full length. 32. Stretch the passenger harness to full length. 33. Completely cover the windshield and front door window openings with a drop cloth. 34. Place a power source, 12 V minimum, 2 A minimum (e.g., a vehicle battery) near the shorted end of the harness. 35. Separate the two ends of the driver frontal air bag deployment harness wires. 36. Connect the driver frontal air bag deployment harness wires to the power source in order to deploy the inflatable restraint steering wheel module. 37. Disconnect the driver frontal air bag deployment harness wires from the power source. 38. Separate the two ends of the passenger frontal air bag deployment harness wires. 39. Connect the passenger frontal air bag deployment harness wires to the power source in order to deploy the inflatable restraint IP module. 40. Disconnect the passenger frontal air bag deployment harness wires from the power source. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10108 41. Twist together one end of each wire on the driver frontal air bag deployment harness in order to short the wires. 42. Twist together one end of each wire on the passenger frontal air bag deployment harness in order to short the wires. 43. Remove the drop cloth from the vehicle. 44. Disconnect both harnesses from the vehicle. 45. Discard the harnesses. 46. Scrap the vehicle in the same manner as a non-SIR equipped vehicle. 47. If one or both of the modules did not deploy, perform the following steps: 47.1. Remove the undeployed modules from the vehicle. 47.2. Temporarily store the modules. 47.3. Call the Technical Assistance Group for further assistance. Handling A Deployed Steering Wheel Inflator Module After the inflator module has deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates), and by-products of the chemical reaction. The deployment reaction produces sodium hydroxide dust (similar to lye soap). The sodium hydroxide quickly reacts with the atmospheric moisture. This atmospheric moisture converts the sodium hydroxide into sodium carbonate and sodium bicarbonate (baking soda). Therefore, you will probably find no sodium hydroxide present after the deployment. Gloves and safety glasses are recommended, however, as a precaution. Gloves and safety glasses help to prevent possible irritation of the skin or eyes. Inflatable Restraint Instrument Panel Module Replacement CAUTION: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module ^ Make sure the bag opening points away from you When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the instrument panel upper trim pad. 3. Remove the Connector Position Assurance (CPA) from the inflatable restraint IP module yellow 2-way wiring harness connector. 4. Disconnect the inflatable restraint IP module yellow 2-way wiring harness connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10109 5. Remove the inflatable restraint IP module mounting fasteners (3). 6. Remove the inflatable restraint IP module (1) from the cross-car beam (2). INSTALLATION PROCEDURE 1. Install the inflatable restraint IP module (1) to the cross-car beam (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the inflatable restraint IP module mounting fasteners (3). Tighten Tighten fasteners to 10 N.m (89 lb in). 3. Connect the inflatable restraint IP module yellow 2-way wiring harness connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10110 4. Install the CPA to the inflatable restraint IP module yellow 2-way wiring harness connector. 5. Install the instrument panel upper trim pad. 6. Enable the SIR system. Refer to Enabling the SIR System. Infl Rst Steering Wheel Module Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Insert a flat-bladed screwdriver into one of the four openings in the back of the steering wheel. 3. Turn the screwdriver counterclockwise to disengage the spring from the slot in the module. 4. Pull the module gently away from the steering wheel. 5. Repeat the previous three steps for the remaining openings. 6. Remove the inflator module from the steering wheel. 7. Remove the Connector Position Assurance (CPA) from the driver frontal air bag electrical connector. 8. Disconnect the electrical connector from the back of the module. 9. Rotate the horn contact lead counterclockwise 1/4 turn in order to remove the horn contact lead from the steering column cam tower. INSTALLATION PROCEDURE 1. Install the horn contact lead to the steering column cam tower. 2. Connect the electrical connector to the back of the module. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Handling/Shipping/Scrapping > Page 10111 3. Install the CPA to the module electrical connector. 4. Install the module to the steering wheel by pushing on both the right and left sides of the inflator module until the retaining springs engage. 5. Enable the SIR system. Refer to Enabling the SIR System. Inflatable Restraint Side Impact Module Replacement - Front REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the driver seat. 3. Unclip the J-clip that is along the lower rear seat back. 4. Remove the seat back cover. 5. Remove the driver side air bag fasteners (2). 6. Note the routing of the driver side air bag wiring harness (4) and retaining clip attachments within the driver seat. 7. Remove the driver side air bag wiring harness (4) retaining clips from the driver seat frame. 8. Gently pull the pigtail harness up into the seat back while guiding the harness through the wire triangle of the seat frame. 9. Remove the module (1) from the driver seat back frame. INSTALLATION PROCEDURE 1. Install the module (1) to the seat while guiding the pigtail harness through the trim cup. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the driver side air fasteners (2). Tighten Tighten the driver side air bag fasteners to 10 N.m (89 lb in). 3. Gently pull the driver side air bag wiring harness (4) down into the seat cushion while guiding the harness through the wire triangle of the seat frame. 4. Install the harness retaining clips to the seat frame. 5. Install the seat back cover. 6. Connect together the J-clip that is along the lower rear seat back. 7. Install the driver seat. 8. Enable the SIR system. Refer to Enabling the SIR System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Specifications Inflatable Restraint Sensing and Diagnostic Module: Specifications Inflatable Restraint Sensing and Diagnostic Module Fasteners 10 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Diagrams > Inflatable Restraint Sensing and Diagnostic Module (SDM)(C1) Inflatable Restraint Sensing And Diagnostic Module (SDM) (C1) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Diagrams > Inflatable Restraint Sensing and Diagnostic Module (SDM)(C1) > Page 10117 Inflatable Restraint Sensing And Diagnostic Module (SDM) (C2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Diagrams > Page 10118 Inflatable Restraint Sensing and Diagnostic Module: Service Precautions CAUTION: Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. CAUTION: If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal Injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the Ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Diagrams > Page 10119 Inflatable Restraint Sensing and Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE The inflatable restraint Sensing and Diagnostic Module (SDM) performs the following functions in the SIR system: ^ Energy Reserve - The SDM maintains a 23 Volt Loop Reserve (23 VLR) energy supply to provide deployment energy for the air bags. Ignition voltage can provide deployment energy if the 23 Volt Loop Reserves malfunction. ^ Crash Detection Frontal - The SDM monitors vehicle velocity changes in order to detect frontal crashes that are severe enough to warrant deployment. - Side - The SDM monitors vehicle velocity changes along with SIS information in order to detect side impact crashes that are severe enough to warrant deployment. ^ Air Bag Deployment Frontal - During a frontal crash of sufficient force, the SDM will cause enough current to flow through the frontal inflator modules to deploy the frontal air bags. - Side - During a side crash of sufficient force, the SDM will cause enough current to flow through the side impact module to deploy the driver side air bag. ^ Frontal Crash Recording - The SDM records information regarding the SIR system status during a frontal crash. ^ Side Impact System Malfunction Monitoring - The SDM monitors the SIS. The SIS can communicate the status of the side impact air bag system to the SDM. ^ Malfunction Detection - The SDM performs diagnostic monitoring of the SIR system electrical components. Upon detection of a circuit or component malfunction, the SDM will set a DTC. ^ Malfunction Diagnosis - The SDM displays SIR DTCs and system status information through the use of a scan tool. ^ Driver Notification - The SDM notifies the vehicle driver of SIR system malfunctions by controlling the AIR BAG warning lamp in the instrument cluster via Class 2 serial data. The SDM connects to the SIR wiring harness using the following connector(s): ^ The 18-way connector provides power, ground, and all the required interfaces for frontal air bag deployment. ^ The 8-way connector (AJ7) provides all the required interfaces for side impact sensing and side air bag deployment. The SDM receives power whenever the ignition is ON. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) Inflatable Restraint Sensing and Diagnostic Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module (AJ7) CAUTION: Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. CAUTION: If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the passenger front seat. 3. Remove the passenger front carpet retainer, then roll back the carpet. 4. Remove the Connector Position Assurance (CPA) from the inflatable restraint sensing and diagnostic module (SDM) 8-way wiring harness connector. 5. Disconnect the SDM 8-way wiring harness connector from the SDM. 6. Remove the connector position assurance (CPA) from the SDM 18-way wiring harness connector (2). 7. Disconnect the SDM 18-way wiring harness connector from the SDM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 10122 8. Remove the SDM mounting fasteners (3). 9. Remove the SDM (1) from the floor pan (2). INSTALLATION PROCEDURE 1. Install the SDM (1) to the floor pan (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the SDM mounting fasteners (3). Tighten Tighten fasteners to 10 N.m (89 lb in). 3. Install the SDM 18-way wiring harness connector to the SDM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 10123 4. Install the connector position assurance (CPA) to the SDM 18-way wiring harness connector. 5. Install the SDM 8-way wiring harness connector to the SDM. 6. Install the connector position assurance (CPA) to the SDM 8-way wiring harness connector. 7. Install the carpet and the passenger front carpet retainer. 8. Install the passenger front seat. 9. Enable the SIR system. Refer to Enabling the SIR System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 10124 Inflatable Restraint Sensing and Diagnostic Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module (AK5) CAUTION: Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. CAUTION: If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the passenger front seat. 3. Remove the passenger front carpet retainer, then roll back the carpet. 4. Remove the Connector Position Assurance (CPA) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector. 5. Disconnect the SDM wiring harness connector from the SDM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 10125 6. Remove the SDM mounting fasteners (3). 7. Remove the SDM (1) from the floor pan (2). INSTALLATION PROCEDURE 1. Install the SDM (1) to the floor pan (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the SDM mounting fasteners (3). Tighten Tighten fasteners to 10 N.m (89 lb in). 3. Install the SDM wiring harness connector to the SDM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 10126 4. Install the connector position assurance (CPA) to the SDM wiring harness connector. 5. Install the carpet and the passenger front carpet retainer. 6. Install the passenger front seat. 7. Enable the SIR system. Refer to Enabling the SIR System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Safety Switch/Connector > Component Information > Locations > Drivers Preliminary, Early Release Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Safety Switch/Connector > Component Information > Locations > Drivers > Page 10131 Preliminary, Early Release Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Safety Switch/Connector > Component Information > Locations > Drivers > Page 10132 Preliminary, Early Release Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Inflatable Restraint Steering Wheel Module Coil Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 10136 Clockspring Assembly / Spiral Cable: Description and Operation INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL The inflatable restraint steering wheel module coil consists of two or more current-carrying coils. The inflatable restraint steering wheel module coil attaches to the steering column. Two of the current-carrying coils allow rotation of the steering wheel while maintaining continuous contact of the driver frontal deployment loop to the inflatable restraint steering wheel module. There is a shorting bar on the yellow 2-way connector near the base of the steering column that connects the inflatable restraint steering wheel module coil to the SIR wiring harness. The shorting bar shorts the circuits to the inflatable restraint steering wheel module coil and inflatable restraint steering wheel module during the disconnection of the yellow 2-way connector. The shorting of the inflatable restraint steering wheel module coil and inflatable restraint steering wheel module circuitry will help prevent unwanted deployment of the air bag when servicing the steering column or other SIR system components. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 10137 Clockspring Assembly / Spiral Cable: Service and Repair INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the inflatable restraint steering wheel module. 3. Remove the upper and lower steering column shrouds. 4. Remove the steering wheel. 5. Disconnect the 8-way inline connector C205 located at the base of the steering column. 6. Remove the wire harness straps from the steering wheel column wire harness. 7. Remove the retaining ring. 8. Remove the inflatable restraint steering wheel module coil from the steering shaft. INSTALLATION PROCEDURE 1. Install the inflatable restraint steering wheel module coil to the steering shaft. 2. Install the retaining ring. 3. Route the lower coil wire harness along the steering column and install the necessary wiring harness straps. 4. Connect the 8-way inline connector C205. 5. Install the steering wheel. 6. Install the upper and lower steering column shrouds. 7. Install the inflatable restraint steering wheel module. 8. Enable the SIR system. Refer to Enabling the SIR System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Inflatable Restraint Side Impact Sensor (LH) (SIS) Fasteners 10 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications > Page 10141 Inflatable Restraint Side Impact Sensor (SIS) (AJ7) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications > Page 10142 Impact Sensor: Service Precautions CAUTION: Be careful when you handle a sensor. Do not strike or bit a sensor. Before applying power to a sensor: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the sensor horizontally on the mounting surface. ^ Point the arrow on the sensor toward the front of the vehicle. ^ Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications > Page 10143 Impact Sensor: Description and Operation INFLATABLE RESTRAINT SIDE IMPACT SENSOR (SIS) The inflatable restraint Side Impact Sensor (SIS) is crash-sensing device used in the detection of side impact collisions. The SIS is located in the LH B pillar. The inflatable restraint side impact sensor is used to perform the following functions: ^ Side Impact Crash Detection - The SIS monitors vehicle velocity changes to detect side impact crashes that are severe enough to warrant deployment. ^ Side Air Bag System Status Communication - The SDM monitors the SIS through two interface circuits. The SIS can communicate the status of the side impact air bag system to the SDM. The SIS connects to the SIR wiring harness using a 2-way connector. The SIS receives power from the SDM when the ignition is ON. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Sensor Replacement Guidelines Impact Sensor: Service and Repair Sensor Replacement Guidelines Preliminary, Early Release Information The Inflatable Restraint Side Impact Sensor (SIS) replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. In this case, a moderate collision where the side of the vehicle, near the LH B pillar, is crushed, bent, or damaged due to a collision, requires replacement of the sensor. The sensor must be replaced whether a driver side air bag has deployed or if the sensor seems to be undamaged. Sensor damage which is not visible, such as a slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the sensor. Do not try to determine whether the sensor is undamaged, replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Sensor Replacement Guidelines > Page 10146 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement INFLATABLE RESTRAINT SIDE IMPACT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the center pillar lower trim. 3. Remove the Connector Position Assurance (CPA) from the inflatable restraint side impact sensor yellow 2-way harness connector. 4. Disconnect the inflatable restraint side impact sensor wiring harness connector. 5. Loosen the two inflatable restraint side impact sensor fasteners (2). 6. Remove the inflatable restraint side impact sensor (1) from the center pillar (3). INSTALLATION PROCEDURE 1. Install the inflatable restraint side impact sensor (1) to the center pillar (3). 2. Tighten the two inflatable restraint side impact sensor (1) fasteners (2). 3. Connect the inflatable restraint side impact sensor yellow 2-way harness connector. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the CPA to the inflatable restraint side impact sensor yellow 2-way connector. Tighten Use only hand tools to tighten the fasteners to 10 N.m (89 lb in). 5. Install the center pillar lower trim. 6. Enable the SIR system. Refer to Enabling the SIR System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Technical Service Bulletins > Side Impact Air Bag - Inflator Module Replacement Side Air Bag: Technical Service Bulletins Side Impact Air Bag - Inflator Module Replacement File In Section: 09 - Restraints Bulletin No.: 01-09-41-007 Date: September, 2001 SERVICE MANUAL UPDATE Subject: Side Impact Air Bag Inflator Module Replacement Models: 2000-2001 Buick Century, Regal 2000-2001 Chevrolet Impala, Monte Carlo This bulletin is being issued to add the following "Caution" statement to the Side Impact Air Bag Inflator Module Replacement procedure in the SIR sub-section of the Service Manual. Please add this information to your Service Manual. This information has been updated within SI2000. If you are using a paper version of this Service Manual, please mark a reference to this bulletin on the affected page. When replacing a Side Impact Air Bag Inflator Module on the above described vehicles, always refer to the following caution. Caution: Following the deployment of a side impact air bag, replace the following parts: ^ The seat back trim ^ The seat back pad ^ The seat back frame Failure to do so may cause future personal injury. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Technical Service Bulletins > Page 10155 Side Air Bag: Specifications Inflatable Restraint Side Impact Module (LH) Fasteners 10 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Technical Service Bulletins > Page 10156 Side Air Bag: Service and Repair INFLATABLE RESTRAINT SIDE IMPACT MODULE REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the driver seat. 3. Unclip the J-clip that is along the lower rear seat back. 4. Remove the seat back cover. 5. Remove the driver side air bag fasteners (2). 6. Note the routing of the driver side air bag wiring harness (4) and retaining clip attachments within the driver seat. 7. Remove the driver side air bag wiring harness (4) retaining clips from the driver seat frame. 8. Gently pull the pigtail harness up into the seat back while guiding the harness through the wire triangle of the seat frame. 9. Remove the module (1) from the driver seat back frame. INSTALLATION PROCEDURE 1. Install the module (1) to the seat while guiding the pigtail harness through the trim cup. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the driver side air fasteners (2). Tighten Tighten the driver side air bag fasteners to 10 N.m (89 lb in). 3. Gently pull the driver side air bag wiring harness (4) down into the seat cushion while guiding the harness through the wire triangle of the seat frame. 4. Install the harness retaining clips to the seat frame. 5. Install the seat back cover. 6. Connect together the J-clip that is along the lower rear seat back. 7. Install the driver seat. 8. Enable the SIR system. Refer to Enabling the SIR System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation Malfunction Lamp / Indicator: Description and Operation Air BAG WARNING LAMP The AIR BAG warning lamp is represented by an icon graphic. Ignition voltage is applied to the AIR BAG warning lamp when the ignition is ON. The inflatable restraint Sensing and Diagnostic Module (SDM) controls the lamp by communicating with the instrument cluster over the Class 2 serial data circuit. The SIR system uses the AIR BAG warning lamp to do the following: ^ Verify proper SIR system operation by commanding the lamp OFF via serial data after seven flashes. The instrument cluster flashes the lamp seven times when the ignition switch is first turned ON. ^ Notify the vehicle driver of electrical system malfunctions which could potentially affect the operation of the SIR system. These malfunctions could result in one or more of the following conditions: Non-deployment of the frontal air bags in the case of a frontal crash - Non-deployment of a side air bag in the case of a side impact crash - Deployment for conditions less severe than intended The AIR BAG warning lamp is the key to driver notification of SIR system malfunctions. Refer to A Diagnostic System Check - SIR for proper lamp operation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Locations > Page 10167 Knee Diverter: Description and Operation KNEE BOLSTER The knee bolsters absorb energy and control the forward movement of the vehicle's front seat occupants during a frontal crash, by limiting leg movement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Bracket Replacement - Knee Bolster (Driver) Knee Diverter: Service and Repair Bracket Replacement - Knee Bolster (Driver) REMOVAL PROCEDURE 1. Remove the LH instrument panel insulator. 2. Remove the steering column opening filler panel. 3. Remove the instrument panel driver knee bolster bracket screws (not shown). 4. Remove the instrument panel knee bolster bracket bolts at the instrument carrier. Remove the instrument panel knee bolster bracket. INSTALLATION PROCEDURE 1. Align the knee bolster bracket to the instrument panel. IMPORTANT: Mandatory torque sequence indicated. 2. Install the knee bolster bracket bolts at the instrument carrier in the sequence shown. Tighten Tighten the driver knee bolster bracket-to-instrument carrier bolts to 10 N.m (89 lb in). 3. Install the instrument panel driver knee bolster bracket screws (not shown). Tighten Tighten the instrument panel driver knee bolster bracket screws to 10 N.m (89 lb in). 4. Install the steering column opening filler panel. 5. Install the LH instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Bracket Replacement - Knee Bolster (Driver) > Page 10170 Knee Diverter: Service and Repair Bracket Replacement - Knee Bolster (Passenger) REMOVAL PROCEDURE 1. Remove the instrument panel (IP) trim pad. 2. Reposition the RH IP accessory wiring junction block. 3. Disconnect the wiring harness retainers from the knee bolster bracket. 4. Remove the IP passenger knee bolster bracket bolts. 5. Remove the IP passenger knee bolster bracket. INSTALLATION PROCEDURE 1. Align the instrument panel (IP) passenger knee bolster bracket to the IP. IMPORTANT: Mandatory torque sequence indicated. 2. Install the IP passenger knee bolster bracket bolts at the instrument carrier in the sequence shown. Tighten Tighten the IP passenger knee bolster bracket bolts to 10 N.m (89 lb in). 3. Connect the wiring harness retainers to the IP passenger knee bolster bracket. 4. Install the RH IP accessory wiring junction block. 5. Install the instrument panel (IP) trim pad. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Specifications Inflatable Restraint Sensing and Diagnostic Module: Specifications Inflatable Restraint Sensing and Diagnostic Module Fasteners 10 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Diagrams > Inflatable Restraint Sensing and Diagnostic Module (SDM)(C1) Inflatable Restraint Sensing And Diagnostic Module (SDM) (C1) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Diagrams > Inflatable Restraint Sensing and Diagnostic Module (SDM)(C1) > Page 10177 Inflatable Restraint Sensing And Diagnostic Module (SDM) (C2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Diagrams > Page 10178 Inflatable Restraint Sensing and Diagnostic Module: Service Precautions CAUTION: Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. CAUTION: If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal Injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the Ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Diagrams > Page 10179 Inflatable Restraint Sensing and Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE The inflatable restraint Sensing and Diagnostic Module (SDM) performs the following functions in the SIR system: ^ Energy Reserve - The SDM maintains a 23 Volt Loop Reserve (23 VLR) energy supply to provide deployment energy for the air bags. Ignition voltage can provide deployment energy if the 23 Volt Loop Reserves malfunction. ^ Crash Detection Frontal - The SDM monitors vehicle velocity changes in order to detect frontal crashes that are severe enough to warrant deployment. - Side - The SDM monitors vehicle velocity changes along with SIS information in order to detect side impact crashes that are severe enough to warrant deployment. ^ Air Bag Deployment Frontal - During a frontal crash of sufficient force, the SDM will cause enough current to flow through the frontal inflator modules to deploy the frontal air bags. - Side - During a side crash of sufficient force, the SDM will cause enough current to flow through the side impact module to deploy the driver side air bag. ^ Frontal Crash Recording - The SDM records information regarding the SIR system status during a frontal crash. ^ Side Impact System Malfunction Monitoring - The SDM monitors the SIS. The SIS can communicate the status of the side impact air bag system to the SDM. ^ Malfunction Detection - The SDM performs diagnostic monitoring of the SIR system electrical components. Upon detection of a circuit or component malfunction, the SDM will set a DTC. ^ Malfunction Diagnosis - The SDM displays SIR DTCs and system status information through the use of a scan tool. ^ Driver Notification - The SDM notifies the vehicle driver of SIR system malfunctions by controlling the AIR BAG warning lamp in the instrument cluster via Class 2 serial data. The SDM connects to the SIR wiring harness using the following connector(s): ^ The 18-way connector provides power, ground, and all the required interfaces for frontal air bag deployment. ^ The 8-way connector (AJ7) provides all the required interfaces for side impact sensing and side air bag deployment. The SDM receives power whenever the ignition is ON. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) Inflatable Restraint Sensing and Diagnostic Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module (AJ7) CAUTION: Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. CAUTION: If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the passenger front seat. 3. Remove the passenger front carpet retainer, then roll back the carpet. 4. Remove the Connector Position Assurance (CPA) from the inflatable restraint sensing and diagnostic module (SDM) 8-way wiring harness connector. 5. Disconnect the SDM 8-way wiring harness connector from the SDM. 6. Remove the connector position assurance (CPA) from the SDM 18-way wiring harness connector (2). 7. Disconnect the SDM 18-way wiring harness connector from the SDM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 10182 8. Remove the SDM mounting fasteners (3). 9. Remove the SDM (1) from the floor pan (2). INSTALLATION PROCEDURE 1. Install the SDM (1) to the floor pan (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the SDM mounting fasteners (3). Tighten Tighten fasteners to 10 N.m (89 lb in). 3. Install the SDM 18-way wiring harness connector to the SDM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 10183 4. Install the connector position assurance (CPA) to the SDM 18-way wiring harness connector. 5. Install the SDM 8-way wiring harness connector to the SDM. 6. Install the connector position assurance (CPA) to the SDM 8-way wiring harness connector. 7. Install the carpet and the passenger front carpet retainer. 8. Install the passenger front seat. 9. Enable the SIR system. Refer to Enabling the SIR System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 10184 Inflatable Restraint Sensing and Diagnostic Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module (AK5) CAUTION: Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. CAUTION: If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the passenger front seat. 3. Remove the passenger front carpet retainer, then roll back the carpet. 4. Remove the Connector Position Assurance (CPA) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector. 5. Disconnect the SDM wiring harness connector from the SDM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 10185 6. Remove the SDM mounting fasteners (3). 7. Remove the SDM (1) from the floor pan (2). INSTALLATION PROCEDURE 1. Install the SDM (1) to the floor pan (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the SDM mounting fasteners (3). Tighten Tighten fasteners to 10 N.m (89 lb in). 3. Install the SDM wiring harness connector to the SDM. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing and Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 10186 4. Install the connector position assurance (CPA) to the SDM wiring harness connector. 5. Install the carpet and the passenger front carpet retainer. 6. Install the passenger front seat. 7. Enable the SIR system. Refer to Enabling the SIR System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions CAUTION: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserve energy supply. The reserve energy supply provides deployment power for the air bags. Deployment power is available for as much as 10 seconds after disconnecting the vehicle power by any of the following methods: ^ Turn OFF the ignition. ^ Remove the fuse that provides power to the SDM. ^ Disconnect the vehicle battery from the vehicle electrical system. Disabling the SIR system prevents deploying of the air bags from the reserve energy supply power. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the LH instrument panel access hole cover. 5. Remove the SDM Fuse from the fuse block. IMPORTANT: With the SDM Fuse removed and the ignition ON, The AIR BAG warning lamp illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the RH instrument panel access hole cover. 7. Unclip the frontal air bags yellow 4-way connector from the metal rail. 8. Remove the Connector Position Assurance (CPA) from the frontal air bags yellow 4-way connector. 9. Disconnect the frontal air bags yellow 4-way connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 10193 10. Remove the connector position assurance (CPA) from the driver side air bag yellow 2-way connector (4) located under the driver seat, if the vehicle is equipped with a driver side air bag. 11. Disconnect the driver side air bag yellow 2-way connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 10194 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Connect the driver side air bag yellow 2-way connector (4) located under the driver seat, if the vehicle is equipped with a driver side air bag. 2. Install the CPA to the driver side air bag yellow 2-way connector. 3. Connect the frontal air bags yellow 4-way connector located at the RH side of the instrument panel. 4. Install the CPA to the frontal air bags yellow 4-way connector. 5. Connect the frontal air bags yellow 4-way connector to the metal rail. 6. Instal the RH instrument panel access hole cover. 7. Install the SDM fuse to the LH fuse block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 10195 8. Install the LH instrument panel access hole cover. 9. Staying well away from the airbags, turn ON the ignition. 9.1. The AIR BAG warning lamp will flash seven times. 9.2. The AIR BAG warning lamp will then turn OFF. 10. Perform A Diagnostic System Check SIR if the AIR BAG warning lamp does not operate as described. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Top Teather Attachment Kits Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Top Teather Attachment Kits Bulletin No.: 99-09-40-004a Date: April 12, 2005 INFORMATION Subject: Top Tether Hardware Package for Child Restraint Seats Models: 1989-2002 Passenger Cars, Light Duty Trucks and Multi-Purpose Passenger Vehicles (Except EV1 and Prizm) Supercede: This bulletin is being revised to add the 2000-2002 model years. Please discard Corporate Bulletin Number 99-09-40-009 (Section 09 - Restraints). Important: GM of Canada and IPC Dealers are not authorized to utilize this service bulletin. Beginning in August, 1997 General Motors began providing Child Restraint Seat Top Tether Hardware Packages to customers in the United States who requested them. The Top Tether Hardware Package contains the necessary hardware for anchoring a forward facing child restraint seat top tether. One Child Restraint Seat Top Tether Hardware Package will be provided per vehicle to the retail customer at no charge for installation. Charges for installation of additional Top Tether Hardware Packages per vehicle are the responsibility of the customer. Most forward facing child restraint seats (CRS) sold in the United States prior to calendar year 1999 were not sold with top tether straps, but have provisions for them. Top tethers, which are required in Canada, can help to better secure the seat in the vehicle. When a forward facing CRS including a top tether is used, specially designed components must be used to secure the child seat top tether. These components are included in the Hardware Package from GMSPO. Top tethers are not normally required or used with rearward facing infant restraint seats. Rearward facing infant restraint seats should never be secured in the front seat of an air bag equipped vehicle unless the vehicle is equipped with an air bag de-activation (shut-off) switch and the switch has been used to turn the air bag off. Should a retail customer request installation of a Tether Hardware Package at the time of sale or delivery, it is to be installed at no charge to the owner. The labor to install a Tether Hardware Package prior to delivery of a new vehicle to the customer is considered to be part of the delivery "get ready process", and as such, is not claimable. Claiming for the cost and applicable handling allowance of the proper Tether Hardware Package used in the installation is allowed. If the customer requests installation of a Tether Hardware Package some time after delivery, the package is to be provided free of charge. Hardware Packages include installation instructions which are easily followed and can be installed by most customers. However, should the customer request the dealership's assistance to install the Tether Hardware Package, it is to be installed at no charge to the customer and the labor may be claimed. All claims submitted for installation labor of an approved Tether Hardware Package must be supported by a signed customer work order. Additional Hardware Packages and installation charges are the responsibility of the customer. In addition, passenger vehicle deliveries, including vans and sport utilities for daily rental usage, may have one tether hardware package supplied. Additional packages are the owner's responsibility. Dealers may claim appropriate parts under these circumstances. Sufficient quantities of parts should be ordered in advance of the arrival of vehicles to avoid delays. Important: When installing a Child Restraint Seat Top Tether Hardware Package, follow the installation instructions included in the package. Additional information about specific mounting locations and installations may be available in the Seat Belt Section (Sections 9, 10-10, 10-11 or 10A) I of the appropriate Service Manual, or the Restraints section of SI. Any questions regarding this policy should be directed to your Area Manager, Parts or Service. Parts Information For Top Tether Hardware Package part numbers and usage, see Group 14.870 (passenger cars & U-van), or Group 16.710 (Light Duty Truck) of the appropriate GMSPO Parts Catalog. In addition, they can also be found in Accessories Group 21.042. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Top Teather Attachment Kits > Page 10201 Warranty Information The dealership will be reimbursed for the parts and labor, if applicable, through the submission of a regular warranty claim. All claims submitted must be supported by a signed customer work order. Purchase and installation of additional Hardware Packages is the responsibility of the customer. For Top Tether Hardware Packages installed in the United States, submit as a normal warranty claim using the labor operations and time allowances shown. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Page 10202 Child Seat Tether Attachment: Specifications Child Seat Tether Bracket Screws 20 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Page 10203 Child Seat Tether Attachment: Service and Repair CHILD RESTRAINT TETHER ANCHOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The child seat tether brackets have an anti-rotation tab. You must rotate this tab 90 degrees (Impala only) in order to remove or install the tether to the rear shelf. 1. Remove the rear shelf trim panel. 2. Remove the screws from the child seat tether brackets. 3. Rotate the child seat tether brackets 90 degrees (Impala only) in order to remove the child seat tether brackets from the slot. 4. Remove the child seat tether brackets from the rear shelf. INSTALLATION PROCEDURE 1. Position the child seat tether brackets to the slot in the rear shelf. 2. Rotate the child seat tether brackets 90 degrees (Impala only) in order to install the child seat tether brackets into the slot. NOTE: Refer to Fastener Notice in Service precautions. 3. Install the screws to the child seat tether brackets. Tighten Tighten the screws to 20 N.m (15 lb ft). 4. Install the rear shelf trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications Seat Belt: Specifications Anchor Plate Nut (Impala) 42 Nm Seat Belt Anchor Nut 42 Nm Rear Seat Center Belt Nuts 42 Nm Shoulder Belt Guide Adjuster Bracket Bolts 42 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications > Page 10207 Seat Belt: Service and Repair SEAT BELT REPLACEMENT - CENTER REAR REMOVAL PROCEDURE 1. Remove the rear seat cushion. 2. Remove the nuts from the center rear seat belts. 3. Remove the center rear seat belts from the vehicle. INSTALLATION PROCEDURE 1. Position the center rear seat belts to the anchor studs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications > Page 10208 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the nuts to the rear seat center belts. Tighten Tighten the nuts to 42 N.m (31 lb ft). 3. Install the rear seat cushion. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Recalls: > NHTSA00V228003 > Aug > 00 > Recall 00V228003: Seat Belt Buckle Defect Seat Belt Buckle: Recalls Recall 00V228003: Seat Belt Buckle Defect Passenger vehicles, light duty trucks, sport utility vehicles, and mini vans equipped with TRW seat belt buckle assemblies. The buckle base of these seat belt assemblies were not properly heat treated and therefore do not pass the load bearing requirement of Federal Motor Vehicle Safety Standard No. 209, "Seat Belt Assemblies." In the event of a vehicle crash, the occupant may not be properly restrained. Dealers will inspect the vehicle's rear safety belt buckle assembly date codes and, if necessary, will replace any rear safety belt buckle assembly. Owner notification is expected to begin during August 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Buick at 1-800-521-7300; Chevrolet at 1-800-222-1020; GMC at 1-800-462-8782; Oldsmobile at 1-800-442-6537; Pontiac at 1-800-762-2737; or Saturn at 1-800-553-6000. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 10222 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 10228 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > NHTSA00V228003 > Aug > 00 > Recall 00V228003: Seat Belt Buckle Defect Seat Belt Buckle: All Technical Service Bulletins Recall 00V228003: Seat Belt Buckle Defect Passenger vehicles, light duty trucks, sport utility vehicles, and mini vans equipped with TRW seat belt buckle assemblies. The buckle base of these seat belt assemblies were not properly heat treated and therefore do not pass the load bearing requirement of Federal Motor Vehicle Safety Standard No. 209, "Seat Belt Assemblies." In the event of a vehicle crash, the occupant may not be properly restrained. Dealers will inspect the vehicle's rear safety belt buckle assembly date codes and, if necessary, will replace any rear safety belt buckle assembly. Owner notification is expected to begin during August 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Buick at 1-800-521-7300; Chevrolet at 1-800-222-1020; GMC at 1-800-462-8782; Oldsmobile at 1-800-442-6537; Pontiac at 1-800-762-2737; or Saturn at 1-800-553-6000. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints Seat Belt Warning Lamp On/Buckling Issues > Page 10238 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > NHTSA00V228003 > Aug > 00 > Recall 00V228003: Seat Belt Buckle Defect Seat Belt Buckle: All Technical Service Bulletins Recall 00V228003: Seat Belt Buckle Defect Passenger vehicles, light duty trucks, sport utility vehicles, and mini vans equipped with TRW seat belt buckle assemblies. The buckle base of these seat belt assemblies were not properly heat treated and therefore do not pass the load bearing requirement of Federal Motor Vehicle Safety Standard No. 209, "Seat Belt Assemblies." In the event of a vehicle crash, the occupant may not be properly restrained. Dealers will inspect the vehicle's rear safety belt buckle assembly date codes and, if necessary, will replace any rear safety belt buckle assembly. Owner notification is expected to begin during August 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Buick at 1-800-521-7300; Chevrolet at 1-800-222-1020; GMC at 1-800-462-8782; Oldsmobile at 1-800-442-6537; Pontiac at 1-800-762-2737; or Saturn at 1-800-553-6000. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Page 10244 Seat Belt Buckle: Specifications Front Seat Buckle Side Belt Nut (Left Side) 42 Nm Front Seat Buckle Side Belt Nut (Right Side) 42 Nm Seat Belt Buckle Anchor Nut 42 Nm Seat Belt Buckle Anchor Bolt 42 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Left Front Seat Belt Buckle: Service and Repair Left Front REMOVAL PROCEDURE 1. Position the left front seat to the forward position. 2. Remove the nut from the seat belt buckle anchor stud. 3. Disconnect the electrical connector from the seat belt buckle. 4. Remove the seat belt buckle from the left front seat. INSTALLATION PROCEDURE 1. Install the seat belt buckle to the left front seat. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Left Front > Page 10247 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the nut to the seat belt anchor stud. Tighten Tighten the seat belt buckle anchor nut to 42 N.m (31 lb ft). 3. Connect the electrical connector to the seat belt buckle. 4. Position the left front seat to the original position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Left Front > Page 10248 Seat Belt Buckle: Service and Repair Center Front (Split Bench) REMOVAL PROCEDURE 1. Remove the front seat. IMPORTANT: When drilling out the rivet do not enlarge the rivet hole. 2. Using a 1/4-inch (6.35-mm) drill bit, drill out the rivet that retains the front seat belt buckle to the rear of the front seat track. 3. Remove the front seat belt buckle from the front seat track. INSTALLATION PROCEDURE 1. Position the front seat belt buckle anchor to the front seat track. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Left Front > Page 10249 IMPORTANT: The rivet is only used for installation alignment. 2. Install the new rivet which secures the front seat belt buckle to the rear of the front seat track. 3. Install the front seat. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Left Front > Page 10250 Seat Belt Buckle: Service and Repair Right Front REMOVAL PROCEDURE 1. Position the right front seat to the forward position. 2. Remove the nut from the seat belt buckle anchor stud. 3. Disconnect the electrical connector from the seat belt buckle. 4. Remove the seat belt buckle from the right front seat. INSTALLATION PROCEDURE 1. Install the seat belt buckle to the right front seat. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Left Front > Page 10251 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the nut to the seat belt anchor stud. Tighten Tighten the seat belt buckle anchor nut to 42 N.m (31 lb ft). 3. Connect the electrical connector to the seat belt buckle. 4. Position the right front seat to the original position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams Seat Belt Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Technical Service Bulletins > Restraints - Extender Availability For Seat Belt Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt INFORMATION Bulletin No.: 99-09-40-005F Date: June 23, 2010 Subject: Seat Belt Extender Availability Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009‐2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints). Important: DO NOT use belt extenders when securing a child restraint. The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal. Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended. Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender. Parts Information For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada. Warranty Information ^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles. ^ Dealers should not be charging part costs since these extenders are supplied by GM to the dealers. ^ Dealers should not be charging labor costs since the extender can be customer installed. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Specifications Seat Belt Guide Track: Specifications Guide Loop Nut (Impala) 42 Nm Guide Loop Bolt (Monte Carlo) 42 Nm Intermediate Guide Bolts (Impala) 10 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair > Shoulder Belt Guide Adjuster Replacement-Front (Impala) Seat Belt Guide Track: Service and Repair Shoulder Belt Guide Adjuster Replacement-Front (Impala) REMOVAL PROCEDURE 1. Remove the center pillar upper trim panel. 2. Remove the shoulder belt guide adjuster bracket bolts. 3. Remove the shoulder belt guide belt adjuster bracket from the center pillar. INSTALLATION PROCEDURE IMPORTANT: Verify that the release lever is at the top of the adjuster bracket in the full up position. 1. Position the shoulder belt guide adjuster bracket to the center pillar. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bracket bolts to the shoulder belt guide adjuster. Tighten Tighten the bracket bolts to 42 N.m (31 lb ft). 3. Install the trim panel for the upper center pillar. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair > Shoulder Belt Guide Adjuster Replacement-Front (Impala) > Page 10264 Seat Belt Guide Track: Service and Repair Child Shoulder Belt Guide Rerouter Replacement Rear Impala REMOVAL PROCEDURE TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover 1. Push back the rear seat back. 2. Use J 38778 in order to remove the push-pin retainer from the child shoulder belt guide rerouter. 3. Remove the child shoulder belt guide rerouter from the rear quarter lower trim panel. INSTALLATION PROCEDURE 1. Push back the rear seat back. 2. Align the child shoulder belt guide rerouter to the rear quarter lower trim panel. 3. Install the push-pin retainer to the child shoulder belt guide rerouter. Monte Carlo REMOVAL PROCEDURE TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover 1. Push back the rear seat back. 2. Use J 38778 in order to remove the push-pin retainer from the child shoulder belt guide rerouter using the. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair > Shoulder Belt Guide Adjuster Replacement-Front (Impala) > Page 10265 3. Remove the child shoulder belt guide rerouter from the rear quarter lower trim panel. INSTALLATION PROCEDURE 1. Push back the rear seat back. 2. Align the child shoulder belt guide rerouter to the rear quarter rear quarter lower trim panel. 3. Install the push-pin retainer to the child shoulder belt guide rerouter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Specifications Seat Belt Retractor: Specifications Seat Belt Retractor Bolt (Impala) 42 Nm Seat Belt Retractor Bolt (Monte Carlo) 42 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front Seat Belt Retractor: Service and Repair Left Front Impala REMOVAL PROCEDURE 1. Open the seat belt guide loop cover. 2. Remove the nut from seat belt guide loop. 3. Remove the seat belt guide loop from the guide adjuster bracket. 4. Remove the center pillar lower trim. 5. Remove the bolts from the seat belt intermediate guide. 6. Remove the seat belt intermediate guide from the center pillar. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 10271 7. Remove the seat belt retractor bolt. 8. Remove the seat belt retractor from the center pillar. INSTALLATION PROCEDURE 1. Install the seat belt retractor into the T-slot in the center pillar. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the seat belt retractor bolt. Tighten Tighten the seat belt retractor bolt to 42 N.m (31 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 10272 3. Install the seat belt intermediate guide to the center pillar. 4. Install the seat belt intermediate guide bolts. Tighten Tighten the seat belt intermediate guide bolts to 10 N.m (89 lb in). 5. Install the center pillar lower trim. 6. Position the seat belt guide loop to the guide adjuster bracket. 7. Install the nut to the seat belt guide loop. Tighten Tighten the nut to 42 N.m (31 lb ft). 8. Close the seat belt guide loop cover. Monte Carlo REMOVAL PROCEDURE 1. Open the seat belt guide loop cover. 2. Remove the seat belt guide loop bolt. 3. Remove the seat belt guide loop from the inner upper quarter. 4. Remove the rear quarter lower trim panel. 5. Remove the trim cover from the rear quarter lower trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 10273 6. Remove the seat belt through the opening in the rear quarter lower trim panel. 7. Remove the bolt from the seat belt retractor. 8. Remove the seat belt retractor from the rear quarter inner panel. 9. Pull back the carpet. 10. Remove the bolt from the seat belt anchor. 11. Remove the seat belt from the vehicle. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 10274 1. Install the seat belt anchor to the vehicle NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the anchor bolt to the seat belt buckle. Tighten Tighten the anchor bolt to 42 N.m (31 lb ft). 3. Return the carpet to the original position. 4. Install the seat belt retractor to the rear quarter inner panel. 5. Install the bolt to the seat belt retractor. Tighten Tighten the seat belt retractor bolt to 42 N.m (31 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 10275 6. Install the seat belt through the opening in the rear quarter lower trim panel. 7. Install the trim cover to the rear quarter lower trim panel. 8. Install the rear quarter lower trim panel. 9. Position the guide loop to the rear quarter inner panel. 10. Install the guide loop bolt. Tighten Tighten the guide loop bolt to 42 N.m (31 lb ft). 11. Close the seat belt guide loop cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 10276 Seat Belt Retractor: Service and Repair Right Front Impala REMOVAL PROCEDURE 1. Open the seat belt guide loop cover. 2. Remove the nut from guide loop. 3. Remove the seat belt guide loop from the guide adjuster bracket. 4. Remove the center pillar lower trim. 5. Remove the bolts from the seat belt intermediate guide. 6. Remove the seat belt intermediate guide from the center pillar. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 10277 7. Remove the seat belt retractor bolt. 8. Remove the seat belt retractor from the center pillar. INSTALLATION PROCEDURE 1. Install the seat belt retractor into the T-slot in the center pillar. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the seat belt retractor bolt. Tighten Tighten the seat belt retractor bolt to 42 N.m (31 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 10278 3. Install the seat belt intermediate guide to the center pillar. 4. Install the seat belt intermediate guide bolts. Tighten Tighten the seat belt intermediate guide bolts to 10 N.m (89 lb in). 5. Install the center pillar lower trim. 6. Position the seat belt guide loop to the guide adjuster bracket. 7. Install the nut to the seat belt guide loop. Tighten Tighten the seat belt guide loop nut to 42 N.m (31 lb ft). 8. Close the seat belt guide loop cover. Monte Carlo REMOVAL PROCEDURE 1. Open the seat belt guide loop cover. 2. Remove the seat belt guide loop bolt. 3. Remove the seat belt guide loop from the inner upper quarter. 4. Remove the rear quarter lower trim panel. 5. Remove the trim cover from the rear quarter lower trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 10279 6. Remove the seat belt through the opening in the rear quarter lower trim panel. 7. Remove the bolt from the seat belt retractor. 8. Remove the seat belt retractor from the rear quarter inner panel. 9. Remove the bolt from the seat belt anchor. 10. Remove the seat belt from the vehicle. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 10280 1. Instal the seat belt anchor to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolt to the seat belt anchor. Tighten Tighten the seat belt anchor bolt to 42 N.m (31 lb ft). 3. Install the seat belt retractor to the rear quarter inner panel. 4. Install the bolt to the seat belt retractor. Tighten Tighten the seat belt retractor bolt to 42 N.m (31 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 10281 5. Install the seat belt through the opening in the rear quarter lower trim panel. 6. Install the trim cover to the rear quarter lower trim panel. 7. Install the rear quarter lower trim panel. 8. Position the seat belt guide loop to the rear quarter inner panel. 9. Install the guide loop bolt. Tighten Tighten the seat belt guide loop bolt to 42 N.m (31 lb ft). 10. Close the seat belt guide loop cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 10282 Seat Belt Retractor: Service and Repair Rear Impala-Outer REMOVAL PROCEDURE 1. Remove the rear shelf trim panel. 2. Remove the rear quarter lower trim panel. 3. Remove the rear seat retractor seat belt bolt. 4. Remove the rear seat belt anchor bolt. 5. Remove the rear seat belt retractor from the vehicle. INSTALLATION PROCEDURE IMPORTANT: The anti-rotation tab must be in the proper hole in the rear shelf. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 10283 1. Install the rear seat retractor side belt to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear seat belt retractor bolt. Tighten Tighten the rear seat belt retractor bolt to 42 N.m (31 lb ft). 3. Install the rear seat belt anchor bolt. Tighten Tighten the rear seat belt anchor bolt to 42 N.m (31 lb ft). 4. Install the rear quarter lower trim panel. 5. Install the rear shelf trim panel. Impala-Center REMOVAL PROCEDURE 1. Remove the rear shelf trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 10284 2. Remove the rear seat retractor seat belt bolt. 3. Remove the rear seat belt retractor from the vehicle. INSTALLATION PROCEDURE IMPORTANT: The anti-rotation tab must be in the proper hole in the rear shelf. 1. Install the rear seat retractor side belt to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear seat belt retractor bolt. Tighten Tighten the rear seat belt retractor bolt to 42 N.m (31 lb ft). 3. Install the rear shelf trim panel. Monte Carlo REMOVAL PROCEDURE 1. Remove the rear shelf trim panel. 2. Remove the rear seat retractor seat belt bolt. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 10285 3. Remove the rear seat belt anchor bolt. 4. Remove the rear seat belt retractor from the vehicle. INSTALLATION PROCEDURE IMPORTANT: The anti-rotation tab must be in the proper hole in the rear shelf. 1. Install the rear seat retractor side belt to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear seat belt retractor bolt. Tighten Tighten the rear seat belt retractor bolt to 42 N.m (31 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 10286 3. Install the rear seat belt anchor bolt. Tighten Tighten the rear seat belt anchor bolt to 42 N.m (31 lb ft). 4. Install the rear shelf trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Inflatable Restraint Side Impact Sensor (LH) (SIS) Fasteners 10 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 10291 Inflatable Restraint Side Impact Sensor (SIS) (AJ7) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 10292 Impact Sensor: Service Precautions CAUTION: Be careful when you handle a sensor. Do not strike or bit a sensor. Before applying power to a sensor: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the sensor horizontally on the mounting surface. ^ Point the arrow on the sensor toward the front of the vehicle. ^ Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 10293 Impact Sensor: Description and Operation INFLATABLE RESTRAINT SIDE IMPACT SENSOR (SIS) The inflatable restraint Side Impact Sensor (SIS) is crash-sensing device used in the detection of side impact collisions. The SIS is located in the LH B pillar. The inflatable restraint side impact sensor is used to perform the following functions: ^ Side Impact Crash Detection - The SIS monitors vehicle velocity changes to detect side impact crashes that are severe enough to warrant deployment. ^ Side Air Bag System Status Communication - The SDM monitors the SIS through two interface circuits. The SIS can communicate the status of the side impact air bag system to the SDM. The SIS connects to the SIR wiring harness using a 2-way connector. The SIS receives power from the SDM when the ignition is ON. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Sensor Replacement Guidelines Impact Sensor: Service and Repair Sensor Replacement Guidelines Preliminary, Early Release Information The Inflatable Restraint Side Impact Sensor (SIS) replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. In this case, a moderate collision where the side of the vehicle, near the LH B pillar, is crushed, bent, or damaged due to a collision, requires replacement of the sensor. The sensor must be replaced whether a driver side air bag has deployed or if the sensor seems to be undamaged. Sensor damage which is not visible, such as a slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the sensor. Do not try to determine whether the sensor is undamaged, replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Sensor Replacement Guidelines > Page 10296 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement INFLATABLE RESTRAINT SIDE IMPACT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the center pillar lower trim. 3. Remove the Connector Position Assurance (CPA) from the inflatable restraint side impact sensor yellow 2-way harness connector. 4. Disconnect the inflatable restraint side impact sensor wiring harness connector. 5. Loosen the two inflatable restraint side impact sensor fasteners (2). 6. Remove the inflatable restraint side impact sensor (1) from the center pillar (3). INSTALLATION PROCEDURE 1. Install the inflatable restraint side impact sensor (1) to the center pillar (3). 2. Tighten the two inflatable restraint side impact sensor (1) fasteners (2). 3. Connect the inflatable restraint side impact sensor yellow 2-way harness connector. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the CPA to the inflatable restraint side impact sensor yellow 2-way connector. Tighten Use only hand tools to tighten the fasteners to 10 N.m (89 lb in). 5. Install the center pillar lower trim. 6. Enable the SIR system. Refer to Enabling the SIR System. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams Seat Belt Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Located in the LH instrument panel fuse block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Service and Repair > Antenna Module Replacement Antenna Control Module: Service and Repair Antenna Module Replacement Antenna Module Replacement REMOVAL PROCEDURE 1. Remove the LH rear quarter upper trim panel. 2. Disconnect the antenna amplifier electrical connector and the antenna coaxial cable. The antenna coaxial cable uses a sliding snap-lock. Pull the lock in order to remove the antenna coaxial cable. 3. Detach the black antenna leads from the glass. The upper lead is held to the body metal with a wiring clip. Carefully pry the clip out of the metal. 4. Remove the antenna amplifier bolt. 5. Remove the antenna amplifier. INSTALLATION PROCEDURE 1. Position the antenna amplifier to the LH rear window inner upper panel. Install the antenna amplifier bolt. Tighten Tighten the antenna amplifier bolt to 3 N.m (27 lb in). IMPORTANT: The antenna coaxial cable uses a sliding snap-lock. Holding the sliding lock feature will prevent installation. 2. Connect the antenna amplifier electrical connectors: 2.1. Position the antenna coaxial cable behind the sliding lock feature. 2.2. Install the antenna coaxial cable to the sliding lock feature. IMPORTANT: If the wiring clip is faulty, the wiring clip must be replaced prior to installation. 3. Install the antenna leads to the rear window terminals. Push the wiring clip on the upper lead into the hex hole in the metal. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Service and Repair > Antenna Module Replacement > Page 10314 Antenna Control Module: Service and Repair Coaxial Cable Replacement REMOVAL PROCEDURE 1. Loosen the rear of the headliner in order to gain access. 2. Remove the antenna coaxial cable from the radio antenna module. 3. Remove the rear seat cushion. Refer to Seat Cushion Replacement - Rear in Seats. 4. Remove the rear seat back. 5. Remove the left carpet retainers. 6. Remove the lower center pillar trim panel. 7. Adjust the carpet for access to the wiring harness as required. 8. Remove the left instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Service and Repair > Antenna Module Replacement > Page 10315 9. Adjust the radio for access. Disconnect the antenna coaxial cable from the rear of the radio. Refer to Radio Replacement. 10. Cut off the visible end of the coaxial antenna cable from the wiring harness in the kick panel area. 11. Cut off the visible end of the coaxial antenna cable from the wiring harness in the rear shelf area. INSTALLATION PROCEDURE 1. Install the coaxial antenna cables to the vehicle. Use electrical tape in order to secure the antenna extension cable to the top of the wiring harness. Make sure that the cable is secured to the harness at least every 150 mm (6 in). 2. Connect the coaxial antenna cable to the rear of the radio. Install the radio. IMPORTANT: The antenna coaxial cable uses a sliding snap-lock. Holding the sliding lock feature will prevent installation. 3. Connect the coaxial antenna cable from the radio to the coaxial antenna cable near the kick panel: 3.1. Position the antenna coaxial cable behind the sliding lock feature. 3.2. Install the antenna coaxial cable to the sliding lock feature. 4. Install the left instrument panel insulator. 5. Install the carpet. 6. Install the lower center pillar trim panel. 7. Install the left carpet retainers. 8. Connect the coaxial antenna cable from the body wiring harness to the coaxial antenna cable at the rear shelf area. 9. Install the rear seat back. 10. Install the rear seat cushion. IMPORTANT: The antenna coaxial cable uses a sliding snap-lock. Holding the sliding lock feature will prevent installation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Service and Repair > Antenna Module Replacement > Page 10316 11. Connect the antenna coaxial cable to the radio antenna module. 11.1. Position the antenna coaxial cable behind the sliding lock feature. 11.2. Install the antenna coaxial cable to the sliding lock feature. 12. Install the rear of the headliner. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-46-003B > Feb > 05 > Instruments - GPS System Performance Degradation Antenna, Navigation: Customer Interest Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts > Page 10330 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-003B > Feb > 05 > Instruments - GPS System Performance Degradation Antenna, Navigation: All Technical Service Bulletins Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts > Page 10340 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Phone: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 10345 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 10350 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 10351 Global Positioning System Antenna: Technical Service Bulletins Onstar(R) - Antenna Coupling Revised Procedures File In Section: 08 - Body and Accessories Bulletin No.: 01-08-46-006A Date: December, 2001 SERVICE MANUAL UPDATE Subject: Revised OnStar(R) Antenna Coupling Replacement Procedures Models: 2000-2002 Passenger Cars and Trucks with Glass Mounted Antenna This bulletin is being revised to add the 2002 model year and revise the service procedures. Please discard Corporate Bulletin Number 01-08-46-006 (Section 08 - Body and Accessories). This bulletin is being issued to revise the OnStar(R) inner and outer antenna coupling replacement procedures in the Cellular Communication sub-section of the Body and Accessories section in the appropriate Service Manual. Please use the following to replace the existing information in the Service Manual. This information has been updated within SI2000. If you are using a paper version of this Service Manual, please mark a reference to this bulletin on the affected page in the Cellular Communication sub-section of the Service Manual. Coupling Replacement - Antenna Inner Removal Procedure Important: Use the described adhesion promoter to assure adequate bonding of the coupling to the glass. To obtain maximum adhesion between the new mobile antenna couplings and the glass surface, the couplings and the glass must be kept dry and above 15°C (60°F) during the installation and for 6-8 hours immediately following the installation. Otherwise the new couplings may come off. Also, disregard the drying or curing time information listed in the instructions included in the replacement antenna coupling kits. In the near future, those instructions will be updated with the drying or curing times listed in this bulletin. ^ Do not attempt to reinstall the original cellular couplings using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Disconnect the coaxial cable from the inner coupling of the mobile communication antenna. Notice: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. Use a small, wide-bladed plastic tool to cut the double back tape material while lifting up on the inner antenna coupling. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 10352 1. Clean the inside of the glass with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. Important: The glass adhesion promoter described in the next step must be used to ensure a bonding of the coupling to the glass surface. Failure to use the described adhesion promoter may result in the coupling coming off the glass. 3. Apply Glass Adhesion Promoter, P/N 12378555 (in Canada, use P/N 88901239), to the glass in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. Important: ^ On rear backglass applications the RF connections for the inner antenna coupling should run parallel to the defogger gridline. ^ Align the inner and the outer antenna couplings. ^ Do not touch the adhesive backing on the antenna coupling. 4. Remove the protective film from the adhesive backing on the inner antenna coupling. 5. Align the inner antenna coupling to the existing exterior coupling. 6. Press firmly on all 4 corners and on the center of the antenna inner coupling (2) in order to ensure proper adhesion to the glass (4). Hold pressure on the inner coupling (2) for 10 to 30 seconds. 7. Ensure that no gaps occur between the couplings (5, 2) and the glass (4). 8. Connect the coaxial cable to the inner coupling (2). 9. Keep the vehicle dry. Allow 6 to 8 hours, at 15°C (60° F), for the adhesive to cure after installation. Coupling Replacement - Antenna Outer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 10353 Removal Procedure Important: Use the described adhesion promoter to assure adequate bonding of the coupling to the glass. To obtain maximum adhesion between the new mobile antenna couplings and the glass surface, the couplings and the glass must be kept dry and above 15°C (60° F) during the installation and for the 6-8 hours immediately following the installation. Otherwise the new couplings may come off. Also, disregard the drying or curing time information listed in the instructions included in the replacement antenna coupling kits. In the near future, those instructions will be updated with the drying or curing times listed in this bulletin. ^ Do not attempt to reinstall the original cellular couplings using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Install the inner coupling first if both the inner and the outer coupling are to be replaced. Refer to Coupling Replacement - Antenna Inner. Notice: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. 2. Use a small, wide-bladed plastic tool to cut the double back tape material while lifting up on the outer antenna coupling. Installation Procedure 1. Clean the glass with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. Important: The glass adhesion promoter described in the next step must be used to ensure a bonding of the coupling to the glass surface. Failure to use the described adhesion promoter may result in the coupling coming off the glass. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 10354 3. Apply Glass Adhesion Promoter, P/N 12378555 (in Canada, use P/N 88901239), to the glass in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. Important: ^ Align the outer antenna coupling with the inner coupling. ^ Do not touch the adhesive backing on the antenna coupling. 4. Remove the protective film from the adhesive backing on the outer antenna coupling. 5. Align the outer antenna coupling to the inner antenna coupling. 6. Press firmly on all 4 corners and on the center of the outer antenna coupling (5) in order to ensure proper adhesion to the glass (4). Hold pressure on the outer coupling (5) for 10 to 30 seconds. 7. Ensure that no gaps occur between the couplings (5, 2) and the glass (4). 8. Keep the vehicle dry. Allow 6 to 8 hours, at 15°C (60°F), for the adhesive to cure after installation. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Locations > Component Locations Antenna, Radio: Component Locations Locations View Under the left rear upper quarter trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Locations > Component Locations > Page 10359 Antenna, Radio: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Locations > Component Locations > Page 10360 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Locations > Page 10361 Antenna, Radio: Service and Repair Coaxial Cable Replacement REMOVAL PROCEDURE 1. Loosen the rear of the headliner in order to gain access. 2. Remove the antenna coaxial cable from the radio antenna module. 3. Remove the rear seat cushion. Refer to Seat Cushion Replacement - Rear in Seats. 4. Remove the rear seat back. 5. Remove the left carpet retainers. 6. Remove the lower center pillar trim panel. 7. Adjust the carpet for access to the wiring harness as required. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Locations > Page 10362 8. Remove the left instrument panel insulator. 9. Adjust the radio for access. Disconnect the antenna coaxial cable from the rear of the radio. Refer to Radio Replacement. 10. Cut off the visible end of the coaxial antenna cable from the wiring harness in the kick panel area. 11. Cut off the visible end of the coaxial antenna cable from the wiring harness in the rear shelf area. INSTALLATION PROCEDURE 1. Install the coaxial antenna cables to the vehicle. Use electrical tape in order to secure the antenna extension cable to the top of the wiring harness. Make sure that the cable is secured to the harness at least every 150 mm (6 in). 2. Connect the coaxial antenna cable to the rear of the radio. Install the radio. IMPORTANT: The antenna coaxial cable uses a sliding snap-lock. Holding the sliding lock feature will prevent installation. 3. Connect the coaxial antenna cable from the radio to the coaxial antenna cable near the kick panel: 3.1. Position the antenna coaxial cable behind the sliding lock feature. 3.2. Install the antenna coaxial cable to the sliding lock feature. 4. Install the left instrument panel insulator. 5. Install the carpet. 6. Install the lower center pillar trim panel. 7. Install the left carpet retainers. 8. Connect the coaxial antenna cable from the body wiring harness to the coaxial antenna cable at the rear shelf area. 9. Install the rear seat back. 10. Install the rear seat cushion. IMPORTANT: The antenna coaxial cable uses a sliding snap-lock. Holding the sliding lock feature will prevent installation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Locations > Page 10363 11. Connect the antenna coaxial cable to the radio antenna module. 11.1. Position the antenna coaxial cable behind the sliding lock feature. 11.2. Install the antenna coaxial cable to the sliding lock feature. 12. Install the rear of the headliner. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > BCM - Related Service, Theft Deterrent Relearn Procedure Alarm Module: Technical Service Bulletins BCM - Related Service, Theft Deterrent Relearn Procedure File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-057A Date: May, 2000 INFORMATION Subject: Body Control Module (BCM) Related Service, Theft Deterrent Re-Learn Procedure Models: 2000 Chevrolet Impala, Monte Carlo This bulletin is being revised to update the service procedure and the labor time information. Please discard Corporate Bulletin Number 99-06-O4-057 (Section 6 - Engine/Propulsion System). BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: - The vehicle will not be protected against theft by the Passlock(TM) system. - The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 10369 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (*) You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 10370 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. 47. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 48. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 49. Select Set Options and press Enter. 50. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 51. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 52. Select Set Option Configuration and press Enter. 53. Press the key under the highlighted Done area of the Tech 2 display. 54. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 55. Exit back to the Main Menu screen. 56. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 57. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 58. Turn the ignition switch to OFF and wait 15 seconds. 59. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 60. The Security and Battery messages will begin toggling. 61. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 62. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 63. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 64. The Security and Battery messages will begin toggling. 65. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 66. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 67. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 10371 release the ignition switch to the RUN position (the engine will not crank). 68. The Security and Battery messages will begin toggling. 69. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 70. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 71. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N4800 Computer (Control), Body - 1.1 hrs Replace and Program Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 10372 Alarm Module: Service and Repair Programming Replacement Lock Cylinder, BCM or PCM IMPORTANT: Reprogram the body control module (BCM) with the proper RPO configurations before you perform the learn procedures. When you replace the BCM, the module will learn PASSLOCK Sensor Data Code immediately. However, the existing PCM must learn the new fuel continue password. When you replace a PCM, after programming, these modules will learn the incoming fuel continue password immediately upon receipt of a password message. Once a password message is received, and a password is learned, perform the learn procedure again if you want to change this password. A PCM which was previously installed in another vehicle will have learned the other vehicle's fuel continue password, and will require a learn procedure after programming in order to learn the current vehicle's password. Always use GM Service Parts Operations (SPO) Replacement Parts. 10 Minute Re-Learn Procedure Use this procedure after replacing any of the following components: 1. Lock Cylinders/PASSLOCK Sensors 2. BCM 3. PCM Tech 2 Programming Procedure Use the following procedures in order to program the BCM with the Tech 2 equipment. 1. Connect the Tech 2 Diagnostic tool. 2. Select Request Information under Service Programming. 3. Disconnect the Tech 2 from the vehicle and connect it to a Techline Terminal. 4. On the Techline Terminal, select Theft Module Re-Learn under Service Programming. 5. Disconnect the Tech 2 from the Techline Terminal and connect the Tech 2 to the vehicle. 6. Turn ON the ignition, with the engine OFF. 7. Select VTD Re-Learn under Service Programming. 8. At this point you may disconnect the Tech 2, the Tech 2 is no longer required. 9. Observe the Security telltale, after approximately 10 minutes the telltale will turn OFF. The vehicle is now ready to relearn the PASSLOCK Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. 10. Turn OFF the ignition, and wait 5 seconds. 11. Start the engine. (The vehicle has now learned keys). 12. Using a scan tool, clear any DTCs. 30 Minute Re-Learn Procedure Use this procedure after replacing lock cylinders, PASSLOCK Module/BCM or the PCM (if necessary - see note above). 1. Turn ON the ignition, with the engine OFF. 2. Attempt to start the engine, then release the key to ON (The vehicle will not start). 3. Observe the Security telltale, after approximately 10 minutes the telltale will turn OFF. 4. Turn OFF the ignition, and wait 5 seconds. 5. Repeat steps 1-4 two more times, for a total of 3 cycles and 30 minutes. The vehicle is now ready to relearn the PASSLOCK Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. IMPORTANT: The vehicle learns the PASSLOCK Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. You must turn the ignition OFF before attempting to start the vehicle. 6. Start the engine. (The vehicle has now learned the PASSLOCK Sensor Data Code and/or password.) 7. Using a scan tool, clear any DTCs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Component Locations Keyless Entry Receiver: Component Locations Locations View On the upper center of the instrument panel, next to the DRL ambient light sensor, under the defroster grille. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Component Locations > Page 10378 Keyless Entry Receiver: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Component Locations > Page 10379 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 10380 Remote Control Door Lock Receiver (RCDLR) Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 10381 Keyless Entry Receiver: Service and Repair Remote Control Door Lock Receiver Replacement REMOVAL PROCEDURE 1. Remove the defroster grille. 2. Disengage the remote control door lock receiver retainers. 3. Disconnect the remote control door lock receiver electrical connectors. 4. Remove the remote control door lock receiver. INSTALLATION PROCEDURE 1. Position the remote control door lock receiver to the upper instrument panel. Connect the remote control door lock receiver electrical connectors. 2. Engage the remote control door lock receiver retainers. 3. Install the defroster grille. 4. If a new remote control door lock receiver is being installed, synchronize the transmitter. Refer to Transmitter Synchronization. 5. If a new remote control door lock receiver is being installed, program the transmitter. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Transmitter Programming Keyless Entry Transmitter: Service and Repair Transmitter Programming In the event that a transmitter is lost, program the old and the new transmitters into the memory of the remote control door lock receiver. Up to 4 transmitters may be programmed. IMPORTANT: Once the keyless entry receiver enters the programming/diagnostic mode, the programming of the first transmitter erases all previous transmitter programming information. You must then program all of the transmitters. Program only 1 vehicle remote control door lock receiver at a time. If you program multiple receivers simultaneously, the same transmitter may possibly be programmed to more than 1 remote control door lock receiver. The following procedure describes how to program the remote control door lock transmitters to the remote control door lock receiver using the Tech 2. Perform the following steps: 1.Connect the scan tool to the following components: ^ An applicable power source ^ The vehicle data link connector (DLC) 2. Turn the ignition ON. 3. At the application menu screen, select F0 (body control module). 4. At the body control module screen, select F2 (special functions). 5. At the special functions menu screen, select F3 (program key fobs). 6. Follow the directions on the scan tool display in order to program the transmitters. 7. Press EXIT repeatedly until you view the application menu screen. 8. Disconnect the scan tool from the following components: ^ The accessory power port ^ The vehicle DLC 9. Validate that all the transmitters that were programmed operate properly. Refer to Keyless Entry System Operation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Transmitter Programming > Page 10386 Keyless Entry Transmitter: Service and Repair Transmitter Synchronization IMPORTANT: Loss of transmitter synchronization will occur when the following conditions are present: ^ The batteries on the keyless entry transmitter have been replaced. ^ A keyless entry transmitter has been activated many times when out of range of the vehicle's remote control door lock receiver. In order to resynchronize a transmitter, press and hold the transmitter LOCK and UNLOCK buttons simultaneously for at least 7 seconds. The horn will sound when the resynchronization is successful. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Page 10390 Passlock(TM) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Cellular Phone: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 10399 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Cellular Phone: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 10404 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 05-08-46-004C > Dec > 10 > OnStar(R) Number Incorrect/Incorrectly Assigned Cellular Phone: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 05-08-46-004C > Dec > 10 > OnStar(R) Number Incorrect/Incorrectly Assigned > Page 10410 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 00-08-46-004C > Jan > 08 > OnStar(R) Re-establishing OnStar(R) Communications Cellular Phone: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 02-08-46-006C > Jan > 08 > OnStar(R) Incorrect GPS Position Reported During Call Cellular Phone: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 02-08-46-006C > Jan > 08 > OnStar(R) Incorrect GPS Position Reported During Call > Page 10419 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 02-08-46-004A > Apr > 06 > Cell Phone Error Messages, Bulletin Cancellation Cellular Phone: All Technical Service Bulletins Cell Phone - Error Messages, Bulletin Cancellation Bulletin No.: 02-08-46-004A Date: April 11, 2006 INFORMATION Subject: Cellular Error Messages Received When Trying to Connect to OnStar(R) Models: 2000-2002 Passenger Cars and Light Duty Trucks with Factory-Installed OnStar(R) Supercede: This bulletin is being revised to cancel this bulletin. The Subject information is addressed in Corporate Bulletin Number 03-08-46-004B. Please discard Corporate Bulletin Number 02-08-46-004 (Section 08 - Body & Accessories). Please reference Corporate Bulletin Number 03-08-46-004B for the Subject information. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 01-08-46-004A > Mar > 05 > OnStar(R)/Cell Phone - Integration Cellular Phone: All Technical Service Bulletins OnStar(R)/Cell Phone - Integration Bulletin No.: 01-08-46-004A Date: March 08, 2005 INFORMATION Subject: Vehicle Integration of Cellular Phones and Normal Operating Characteristics Models: 2002 and Prior Passenger Cars and Trucks Supercede: This bulletin is being issued to cancel Corporate Bulletin Number 01-08-46-004. Please discard all copies of Corporate Bulletin Number 01-08-46-004 (Section 08 - Body and Accessories). This bulletin effectively cancels Corporate Bulletin Number 01-08-46-004. OnStar(R) no longer offers cellular phones as part of the OnStar(R) system. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cellular Phone: > 00-08-46-004C > Jan > 08 > OnStar(R) Re-establishing OnStar(R) Communications Cellular Phone: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cellular Phone: > 02-08-46-004A > Apr > 06 > Cell Phone Error Messages, Bulletin Cancellation Cellular Phone: All Technical Service Bulletins Cell Phone - Error Messages, Bulletin Cancellation Bulletin No.: 02-08-46-004A Date: April 11, 2006 INFORMATION Subject: Cellular Error Messages Received When Trying to Connect to OnStar(R) Models: 2000-2002 Passenger Cars and Light Duty Trucks with Factory-Installed OnStar(R) Supercede: This bulletin is being revised to cancel this bulletin. The Subject information is addressed in Corporate Bulletin Number 03-08-46-004B. Please discard Corporate Bulletin Number 02-08-46-004 (Section 08 - Body & Accessories). Please reference Corporate Bulletin Number 03-08-46-004B for the Subject information. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cellular Phone: > 01-08-46-004A > Mar > 05 > OnStar(R)/Cell Phone - Integration Cellular Phone: All Technical Service Bulletins OnStar(R)/Cell Phone - Integration Bulletin No.: 01-08-46-004A Date: March 08, 2005 INFORMATION Subject: Vehicle Integration of Cellular Phones and Normal Operating Characteristics Models: 2002 and Prior Passenger Cars and Trucks Supercede: This bulletin is being issued to cancel Corporate Bulletin Number 01-08-46-004. Please discard all copies of Corporate Bulletin Number 01-08-46-004 (Section 08 - Body and Accessories). This bulletin effectively cancels Corporate Bulletin Number 01-08-46-004. OnStar(R) no longer offers cellular phones as part of the OnStar(R) system. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > DID Digital Display Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > DID Digital Display > Page 10445 Driver/Vehicle Information Display: Locations Driver Information Display Control Module In the front center of the roof headliner. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10448 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10449 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10450 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10451 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10452 Driver/Vehicle Information Display: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10453 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10454 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10455 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10456 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10457 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10458 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10459 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10460 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10461 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10462 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10463 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10464 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10465 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10466 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10467 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10468 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10469 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10470 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10471 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10472 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10473 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10482 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10483 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10484 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10485 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10486 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10487 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10488 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10489 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10490 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10491 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10492 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10493 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10494 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10495 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10496 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10497 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10498 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10499 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10500 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10501 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10502 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10503 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10504 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10505 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10506 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10507 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10508 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10509 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10510 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10511 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10512 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10513 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10514 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10515 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 10521 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 10526 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 10532 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10537 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10538 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10539 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10540 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10541 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10542 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10543 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10544 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10545 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10546 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10547 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10548 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10549 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10550 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10551 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10552 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10553 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10554 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10555 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10556 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10557 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10558 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10559 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10560 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10561 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10562 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10563 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10564 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10565 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10566 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10567 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10568 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10569 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10570 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-64-007A > Sep > 08 > OnStar(R) - Analog Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 10587 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-007 > Dec > 06 > OnStar - Analog-Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar - Analog-Only Systems Information Bulletin No.: 06-08-46-007 Date: December 13, 2006 INFORMATION Subject: Information on OnStar(R) Analog-Only Systems Models: 1996-2001 GM Passenger Cars and Trucks Plus: 2002 Buick LeSabre, Rendezvous 2002-2003 Buick Century, Regal 2002-2005 Buick Park Avenue 2002 Cadillac Eldorado, Escalade Models 2002 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Venture 2002 GMC Denali, Denali XL, Jimmy, Sierra, Yukon, Yukon XL 2002 Oldsmobile Intrigue, Silhouette 2002-2003 Oldsmobile Aurora 2002 Pontiac Aztek, Bonneville, Montana 2002-2003 Pontiac Grand Prix with OnStar(R) (RPO UE1) All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog/Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 10597 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-64-007A > Sep > 08 > OnStar(R) - Analog Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 10614 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-007 > Dec > 06 > OnStar - Analog-Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar - Analog-Only Systems Information Bulletin No.: 06-08-46-007 Date: December 13, 2006 INFORMATION Subject: Information on OnStar(R) Analog-Only Systems Models: 1996-2001 GM Passenger Cars and Trucks Plus: 2002 Buick LeSabre, Rendezvous 2002-2003 Buick Century, Regal 2002-2005 Buick Park Avenue 2002 Cadillac Eldorado, Escalade Models 2002 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Venture 2002 GMC Denali, Denali XL, Jimmy, Sierra, Yukon, Yukon XL 2002 Oldsmobile Intrigue, Silhouette 2002-2003 Oldsmobile Aurora 2002 Pontiac Aztek, Bonneville, Montana 2002-2003 Pontiac Grand Prix with OnStar(R) (RPO UE1) All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog/Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10624 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10625 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10626 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10627 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10628 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10629 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10630 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10631 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10632 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10633 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10634 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10635 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10636 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10637 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10638 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10639 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10640 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10641 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10642 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10643 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10644 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10645 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10646 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10647 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10648 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10649 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10650 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10651 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10652 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10653 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10654 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10655 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10656 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10657 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Technical Service Bulletins > Customer Interest for Garage Door Opener Transmitter: > 01-08-97-002 > Nov > 01 > HomeLink(R) Transmitter - Programming Difficulties Garage Door Opener Transmitter: Customer Interest HomeLink(R) Transmitter - Programming Difficulties File In Section: 08 - Body and Accessories Bulletin No.: 01-08-97-002 Date: November, 2001 INFORMATION Subject: Programming the HomeLink(R) Transmitter Models: 2000-2002 Passenger Cars and Light Duty Trucks with Universal Garage Door Opener (RPO UG1) If you have customers that are having difficulties programming their HomeLink(R) transmitter, you may suggest the following options: ^ The customer may contact HomeLink(R) directly at 1-800-355-3515 for assistance. Assistance is available in English, French and Spanish languages. ^ The customer may also be directed to the HomeLink(R) website at www.homelink.com. The website is user-friendly and actively demonstrates how to program the transmitter. Many newer garage door openers have a "rolling code" feature and the website does a great job of guiding the owner through the entire programming process. The HomeLink(R) phone number, website address, and other useful information can also be found in Section 2 of the Owner's Manual under HomeLink(R) Transmitter. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Garage Door Opener Transmitter: > 01-08-97-002 > Nov > 01 > HomeLink(R) Transmitter - Programming Difficulties Garage Door Opener Transmitter: All Technical Service Bulletins HomeLink(R) Transmitter Programming Difficulties File In Section: 08 - Body and Accessories Bulletin No.: 01-08-97-002 Date: November, 2001 INFORMATION Subject: Programming the HomeLink(R) Transmitter Models: 2000-2002 Passenger Cars and Light Duty Trucks with Universal Garage Door Opener (RPO UG1) If you have customers that are having difficulties programming their HomeLink(R) transmitter, you may suggest the following options: ^ The customer may contact HomeLink(R) directly at 1-800-355-3515 for assistance. Assistance is available in English, French and Spanish languages. ^ The customer may also be directed to the HomeLink(R) website at www.homelink.com. The website is user-friendly and actively demonstrates how to program the transmitter. Many newer garage door openers have a "rolling code" feature and the website does a great job of guiding the owner through the entire programming process. The HomeLink(R) phone number, website address, and other useful information can also be found in Section 2 of the Owner's Manual under HomeLink(R) Transmitter. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions Garage Door Opener Transmitter: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10689 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10690 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10691 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10692 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10693 Garage Door Opener Transmitter: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10694 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10695 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10696 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10697 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10698 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10699 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10700 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10701 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10702 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10703 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10704 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10705 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10706 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10707 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10708 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10709 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10710 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10711 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10712 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10713 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10714 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10715 Garage Door Opener Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation > General Description Garage Door Opener Transmitter: Description and Operation General Description The GDO is part of the Driver Information Center (DIC). The GDO is provided battery voltage at all times. If battery voltage is lost, the GDO unit has a non-serviceable internal power backup supply. The unit is programmed using the customer's hand-held transmitters for their garage door(s), electric entrance gates, or lighting and security systems. The GDO is rolling code capable. Rolling code is a system that allows the code that the customers receiver receives from the GDO to change every time the GDO is used within operating range of the receiver. When the receiver and the GDO are initially programmed together, a code count is established. After that, a new code count is created for every new transmission. The software in the receiver recognizes the GDO code count as valid and accepts the command from the GDO. The GDO is compatible with most, but not all, types and brands of transmitters. If a problem should occur with a compatibility conflict with a transmitter, call HomeLink(TM) at 1-800-355-3515. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation > General Description > Page 10718 Garage Door Opener Transmitter: Description and Operation System Operation The garage door opener (GDO) is a transmitter operating between 288 and 399 Mhz. The power and range of the transmitter is limited to comply with laws governing the generation of Radio Frequency Interference (RFI). The transmitter is programmed by the user to accept the signal generated by the user's transmitter(s), refer to Garage Door Opener Programming - Universal. The three center buttons on the DIC may be programmed for individual transmitter/receiver combinations to control up to three garage door openers, security gates and lighting systems. Each button represents a transmitter code section of the transmitter, operates separately from any other button and may be considered a separate transmitter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation > General Description > Page 10719 Garage Door Opener Transmitter: Description and Operation Circuit Description There are only two circuits, supply and ground, required for the Garage Door Opener (GDO). The ground circuit is to a low noise ground point. The supply is from a HOT AT ALL TIMES fuse. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Garage Door Opener Transmitter: Initial Inspection and Diagnostic Overview Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms in order to identity the correct procedure for diagnosing the system and where the procedure is located. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10722 Garage Door Opener Transmitter: Symptom Related Diagnostic Procedures - Symptoms - Garage Door Opener IMPORTANT: Review the system operation in order to familiarize yourself with the system functions. Refer to Garage Door Opener Operation. Visual/Physical Inspection ^ Inspect for aftermarket devices which could affect the operation of the garage door opener. Refer to Checking Aftermarket Accessories. ^ Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent and Poor Connections in Diagrams. Symptom List Refer to Garage Door Opener Inoperative in order to diagnose the symptom. Diagnostic Chart Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Page 10723 Garage Door Opener Transmitter: Service and Repair GARAGE DOOR OPENER PROGRAMMING IMPORTANT: Do not use the garage door opener (GDO) with any garage door opener that does not have the stop and reverse safety feature. This includes any garage door opener model manufactured before April 1,1982. Be sure that people and objects are clear of the garage door you are programming. The GDO is programmed by using the customer's hand-held transmitter(s). Turn the ignition OFF while programming the GDO transmitter. Follow these steps to program up to 3 channels: 1. If you have previously programmed a transmitter, proceed to Step 2. Otherwise, hold down the 2 outside buttons on the GDO transmitter for approximately 20 seconds, until the light on the GDO transmitter begins to flash rapidly. Then release the buttons. This procedure erases any previous settings and initializes the memory for all 3 channels. 2. Decide which of the 3 channels you want to program to the transmitter you have. 3. Hold the end of the hand-held transmitter against the front surface of the GDO (less than one inch) so you can still see the light. 4. Using both hands, press the hand-held transmitter button and the desired button on the GDO transmitter. Continue to hold both buttons through Step 5. IMPORTANT: The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call HomeLink at 1-800-355-3515 in order to address this problem. 5. Hold down the buttons on both transmitters until you see the light on the GDO transmitter flash slowly and then rapidly. The rapid flashing, which could take up to 90 seconds, indicates that the GDO transmitter has been programmed. Release the buttons on both transmitters when the light starts to flash rapidly. TRAINING THE GDO FOR ROLLING CODE RECEIVERS This procedure is for training the customer's rolling code garage door openers to their GDO transmitter. The GDO must already be programmed to its hand-held transmitter. The training process below must be completed within 30 seconds or it must be repeated. 1. Locate the train button on the garage door opener receiver. (Refer to the operator's manual for the garage door opener (or call HomeLink at 1-800-355-3515 for assistance). Follow instructions for the garage door opener in order to determine when the unit is in train mode. 2. Return to the GDO transmitter in the vehicle, and press the button that you want trained for rolling codes 3 times, for 1 second each time. 3. Press the button used again in order to verify that the GDO transmitter has been programmed. You may use either the hand-held transmitter or the GDO to open the garage door. The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call HomeLink at 1-800-355-3515 in order to address compatibility concerns. ERASING CHANNELS To erase programmed channels, hold down the 2 outside buttons until the light on the GDO transmitter begins to flash. Individual channels cannot be erased, but can be reprogrammed using the Garage Door Opener Programming and the Training GDO for Rolling Code Receivers procedures. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Page 10724 Special Tools And Equipment Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 10730 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 10731 Global Positioning System Antenna: Technical Service Bulletins Onstar(R) - Antenna Coupling Revised Procedures File In Section: 08 - Body and Accessories Bulletin No.: 01-08-46-006A Date: December, 2001 SERVICE MANUAL UPDATE Subject: Revised OnStar(R) Antenna Coupling Replacement Procedures Models: 2000-2002 Passenger Cars and Trucks with Glass Mounted Antenna This bulletin is being revised to add the 2002 model year and revise the service procedures. Please discard Corporate Bulletin Number 01-08-46-006 (Section 08 - Body and Accessories). This bulletin is being issued to revise the OnStar(R) inner and outer antenna coupling replacement procedures in the Cellular Communication sub-section of the Body and Accessories section in the appropriate Service Manual. Please use the following to replace the existing information in the Service Manual. This information has been updated within SI2000. If you are using a paper version of this Service Manual, please mark a reference to this bulletin on the affected page in the Cellular Communication sub-section of the Service Manual. Coupling Replacement - Antenna Inner Removal Procedure Important: Use the described adhesion promoter to assure adequate bonding of the coupling to the glass. To obtain maximum adhesion between the new mobile antenna couplings and the glass surface, the couplings and the glass must be kept dry and above 15°C (60°F) during the installation and for 6-8 hours immediately following the installation. Otherwise the new couplings may come off. Also, disregard the drying or curing time information listed in the instructions included in the replacement antenna coupling kits. In the near future, those instructions will be updated with the drying or curing times listed in this bulletin. ^ Do not attempt to reinstall the original cellular couplings using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Disconnect the coaxial cable from the inner coupling of the mobile communication antenna. Notice: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. Use a small, wide-bladed plastic tool to cut the double back tape material while lifting up on the inner antenna coupling. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 10732 1. Clean the inside of the glass with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. Important: The glass adhesion promoter described in the next step must be used to ensure a bonding of the coupling to the glass surface. Failure to use the described adhesion promoter may result in the coupling coming off the glass. 3. Apply Glass Adhesion Promoter, P/N 12378555 (in Canada, use P/N 88901239), to the glass in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. Important: ^ On rear backglass applications the RF connections for the inner antenna coupling should run parallel to the defogger gridline. ^ Align the inner and the outer antenna couplings. ^ Do not touch the adhesive backing on the antenna coupling. 4. Remove the protective film from the adhesive backing on the inner antenna coupling. 5. Align the inner antenna coupling to the existing exterior coupling. 6. Press firmly on all 4 corners and on the center of the antenna inner coupling (2) in order to ensure proper adhesion to the glass (4). Hold pressure on the inner coupling (2) for 10 to 30 seconds. 7. Ensure that no gaps occur between the couplings (5, 2) and the glass (4). 8. Connect the coaxial cable to the inner coupling (2). 9. Keep the vehicle dry. Allow 6 to 8 hours, at 15°C (60° F), for the adhesive to cure after installation. Coupling Replacement - Antenna Outer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 10733 Removal Procedure Important: Use the described adhesion promoter to assure adequate bonding of the coupling to the glass. To obtain maximum adhesion between the new mobile antenna couplings and the glass surface, the couplings and the glass must be kept dry and above 15°C (60° F) during the installation and for the 6-8 hours immediately following the installation. Otherwise the new couplings may come off. Also, disregard the drying or curing time information listed in the instructions included in the replacement antenna coupling kits. In the near future, those instructions will be updated with the drying or curing times listed in this bulletin. ^ Do not attempt to reinstall the original cellular couplings using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Install the inner coupling first if both the inner and the outer coupling are to be replaced. Refer to Coupling Replacement - Antenna Inner. Notice: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. 2. Use a small, wide-bladed plastic tool to cut the double back tape material while lifting up on the outer antenna coupling. Installation Procedure 1. Clean the glass with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. Important: The glass adhesion promoter described in the next step must be used to ensure a bonding of the coupling to the glass surface. Failure to use the described adhesion promoter may result in the coupling coming off the glass. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 10734 3. Apply Glass Adhesion Promoter, P/N 12378555 (in Canada, use P/N 88901239), to the glass in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. Important: ^ Align the outer antenna coupling with the inner coupling. ^ Do not touch the adhesive backing on the antenna coupling. 4. Remove the protective film from the adhesive backing on the outer antenna coupling. 5. Align the outer antenna coupling to the inner antenna coupling. 6. Press firmly on all 4 corners and on the center of the outer antenna coupling (5) in order to ensure proper adhesion to the glass (4). Hold pressure on the outer coupling (5) for 10 to 30 seconds. 7. Ensure that no gaps occur between the couplings (5, 2) and the glass (4). 8. Keep the vehicle dry. Allow 6 to 8 hours, at 15°C (60°F), for the adhesive to cure after installation. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10743 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10744 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10745 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10746 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10747 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10748 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10749 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10750 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10751 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10752 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10753 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10754 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10755 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10756 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10757 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10758 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10759 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10760 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10761 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10762 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10763 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10764 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10765 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10766 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10767 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10768 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10769 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10770 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10771 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10772 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10773 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10774 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10775 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 10776 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 10782 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 10787 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 10793 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10-08-44-006 > Oct > 10 > Navigation - Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10802 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10803 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10804 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10805 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10806 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10807 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10808 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10809 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10810 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10811 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10812 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10813 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10814 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10815 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10816 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10817 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10818 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10819 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10820 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10821 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10822 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10823 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10824 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10825 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10826 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10827 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10828 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10829 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10830 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10831 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10832 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10833 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10834 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10835 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-64-007A > Sep > 08 > OnStar(R) - Analog Only Systems Information Navigation System: All Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-023 > Jun > 08 > Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 10856 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 07-08-44-007 > Apr > 07 > Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) Number Incorrect/Incorrectly Assigned Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) Number Incorrect/Incorrectly Assigned > Page 10866 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10-08-44-006 > Oct > 10 > Navigation Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-64-007A > Sep > 08 > OnStar(R) Analog Only Systems Information Navigation System: All Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-46-004 > Aug > 08 > OnStar(R) Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-023 > Jun > 08 > Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 00-08-46-004C > Jan > 08 > OnStar(R) Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) Incorrect GPS Position Reported During Call Navigation System: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) Incorrect GPS Position Reported During Call > Page 10891 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 07-08-44-007 > Apr > 07 > Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10905 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10906 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10907 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10908 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10909 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10910 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10911 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10912 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10913 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10914 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10915 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10916 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10917 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10918 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10919 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10920 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10921 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10922 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10923 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10924 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10925 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10926 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10927 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10928 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10929 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10930 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10931 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10932 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10933 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10934 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10935 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10936 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10937 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 10938 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Component Locations Amplifier: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Component Locations > Page 10964 Locations View Audio Power Booster (UW6) In the rear compartment, underneath the rear package shelf. RPO UW6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Component Locations > Page 10965 Amplifier: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Component Locations > Page 10966 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Page 10967 Amplifier: Service and Repair Amplifier Replacement REMOVAL PROCEDURE 1. Remove the rear window trim panel. IMPORTANT: Inspect the retainers and the foam washers. Faulty retainers and washers must be replaced. 2. Disengage the amplifier retainers from the rear window panel. 3. Disconnect the electrical connectors from the amplifier. 4. Remove the amplifier. INSTALLATION PROCEDURE 1. Position the amplifier to the rear window panel. IMPORTANT: Make sure all of the foam washers are installed. Faulty retainers must be replaced. 2. Align the retainers to the openings in the rear window panel. Carefully push in the retainers in order to secure the amplifier. 3. Connect the electrical connectors to the amplifier. 4. Install the rear window trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Locations CD Changer: Locations Mounted in the rear compartment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Locations > Page 10972 CD Changer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Specifications Speaker: Specifications Speaker Screw (Front) 2 Nm Speaker Grille Nuts 2 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Component Locations Speaker: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Component Locations > Page 10983 Locations View Radio Front Door Speaker Lower front corner of the front door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Component Locations > Page 10984 Locations View Speaker - Rear Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Component Locations > Page 10985 Locations View RPO UQ3/UW6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Component Locations > Page 10986 Speaker: Connector Locations Speaker Connector, Rear Locations View RPO UQ3/UW6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Component Locations > Page 10987 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Component Locations > Page 10988 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Door Speaker: Service and Repair Speaker Replacement - Front Door Speaker Replacement - Front Door REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Remove the door speaker screws. 3. Pull the speaker towards you. Disconnect the electrical connector from the speaker. 4. Remove the speaker. INSTALLATION PROCEDURE 1. Connect the electrical connector to the speaker. Position the speaker to the door. 2. Install the speaker. 3. Install the speaker screws. Tighten Tighten the speaker screws to 2 N.m (18 lb in). IMPORTANT: Due to the lower trim fasteners close proximity to the speaker cone, the door trim must be installed with care. 4. Install the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Door > Page 10991 Speaker: Service and Repair Speaker Replacement - Rear Shelf Speaker Replacement - Rear Shelf REMOVAL PROCEDURE 1. Remove the rear window trim panel. 2. Disengage the speaker retaining tab. Remove the speaker alignment tabs from the opening in the rear window panel. The speaker seal may have bonded with the shelf metal. Carefully pry the housing away from the metal while holding the speaker retaining tab in order to remove the speaker. 3. Disconnect the electrical connector from the rear speaker. 4. Remove the rear speaker. INSTALLATION PROCEDURE 1. Connect the electrical connector to the rear speaker. Position the rear speaker to the rear window panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Door > Page 10992 2. Install the speaker alignment tabs into the opening in the rear window panel. Engage the rear speaker retaining tab. 3. Install the rear window trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Door > Page 10993 Speaker: Service and Repair Speaker Grille Replacement - Rear Speaker Grille Replacement - Rear REMOVAL PROCEDURE 1. Remove the rear window shelf trim panel. 2. Remove the nuts from the rear speaker grille. 3. Release the rear speaker grille retainer tabs in order to remove the grille from the rear window trim panel. INSTALLATION PROCEDURE 1. Align the rear speaker grille to the rear window trim panel. 2. Install the rear speaker grille to the rear window trim panel pressing into place until the retainer tabs are fully seated. 3. Install the nuts to the rear speaker grille. Tighten Tighten the speaker grille nuts to 2 N.m (18 lb in). 4. Install the rear window shelf trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Cassette Player - Cleaning and Maintenance Tape Player: Technical Service Bulletins Cassette Player - Cleaning and Maintenance File In Section: 08 - Body and Accessories Bulletin No.: 99-08-44-008 Date: October, 1999 INFORMATION Subject: Cassette Player Cleaning and Maintenance Models: 1998-2000 All Passenger Cars and Trucks with Cassette Tape Players Radios are being replaced and charged to warranty because the customer has commented on any one or more of the following conditions: ^ The tape plays slow. ^ The tape sounds muffled. ^ The tape sounds garbled. ^ The tape is inoperative. ^ The tape is becoming stuck in the cassette player. When the radio is returned to the repair center, the cause is found to be a dirty tape head. When a customer comes in with any of above conditions concerning their cassette player, dealers should perform the normal cassette player maintenance. Maintenance procedures are in the Owner's Manual and/or the Service Manual. The customer must be charged for this service. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Page 10998 Tape Player: Service and Repair TOOLS REQUIRED J 39916-A CD and Cassette Diagnostic Kit Follow the recommended cleaning schedule: 1. Clean the cassette player every 15 hours for the best performance. 2. Clean the cassette player every 50 hours in order to prevent damage to the tape head. Clean the following 2 parts on the tape player: ^ The head ^ The capstan Leave the tape player in the vehicle, since you can reach the parts through the tape door. Perform this service at least every 50 hours of cassette operation. After 50 hours of tape play, CLN (Clean) appears on the display as a reminder. Although the system will still function when this message is displayed, the following conditions may occur until the head and the capstan are cleaned: ^ Reduced sound quality ^ Damage to the cassette tapes After cleaning the cassette tape player, press and hold EJECT for 5 seconds in order to reset the CLN indicator. The radio displays - -- in order to show that the clean feature has been reset. Failure to clean the cassette player regularly may cause the following conditions: ^ Reduced sound quality ^ Damage to the cassettes ^ Damage to the mechanism Keep the cassette tapes correctly stored in their plastic cases away from the following conditions: ^ Contaminants ^ Direct sunlight ^ Extreme heat Failure to correctly store the cassette tapes may cause the following conditions: ^ Improper operation of the cassette tapes ^ Premature failure of the tape player The cassettes are subject to wear. The sound quality may degrade over time. Before servicing a tape player, verify that the following conditions exist: ^ The cassette tape is in good condition. ^ The tape player is clean. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Page 10999 Clean the tape player at least after every 50 hours of use in order to provide optimum performance. The radio displays CLN as a reminder every 50 hours. If a reduction in the sound quality occurs, regardless of when the tape player was last cleaned, play a different cassette tape in order to see if the tape or the tape player is at fault. If the second cassette tape results in no improvement in sound quality, clean the tape player. Use a scrubbing action, non-abrasive cleaning cassette (part of J39916-A) for proper tape player cleaning. This cleaner is a wet-type cleaning system. The wet-type cleaning system uses a cleaning cassette with pads. The pads scrub the tape head as the hubs of the cleaner cassette turn. If you use this type of cleaner, the following conditions may occur: ^ The radio displays an error. ^ The cartridge ejects. These conditions are normal and is the result of an added feature in the tape player that detects broken tapes. If an error occurs, insert the cleaning cassette at least 3 times in order to thoroughly clean the tape player. The following steps will enable the radio to accept the tape: 1. Press and hold the Tape/CD button for 5 seconds. 2. Radio will display READY. 3. Insert cleaner. 4. Press and hold Eject button to reset CLN. You can also use a non-scrubbing action, wet-type cleaner. This type of cleaner uses a cassette with a fabric belt which cleans the tape head. This type of cleaning cassette will not cause an error, but may not clean the tape player as thoroughly as the scrubbing type cleaner. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Located in the LH instrument panel fuse block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > BCM - Related Service, Theft Deterrent Relearn Procedure Alarm Module: Technical Service Bulletins BCM - Related Service, Theft Deterrent Relearn Procedure File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-057A Date: May, 2000 INFORMATION Subject: Body Control Module (BCM) Related Service, Theft Deterrent Re-Learn Procedure Models: 2000 Chevrolet Impala, Monte Carlo This bulletin is being revised to update the service procedure and the labor time information. Please discard Corporate Bulletin Number 99-06-O4-057 (Section 6 - Engine/Propulsion System). BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: - The vehicle will not be protected against theft by the Passlock(TM) system. - The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 11009 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (*) You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 11010 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. 47. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 48. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 49. Select Set Options and press Enter. 50. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 51. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 52. Select Set Option Configuration and press Enter. 53. Press the key under the highlighted Done area of the Tech 2 display. 54. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 55. Exit back to the Main Menu screen. 56. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 57. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 58. Turn the ignition switch to OFF and wait 15 seconds. 59. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 60. The Security and Battery messages will begin toggling. 61. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 62. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 63. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 64. The Security and Battery messages will begin toggling. 65. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 66. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 67. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 11011 release the ignition switch to the RUN position (the engine will not crank). 68. The Security and Battery messages will begin toggling. 69. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 70. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 71. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N4800 Computer (Control), Body - 1.1 hrs Replace and Program Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 11012 Alarm Module: Service and Repair Programming Replacement Lock Cylinder, BCM or PCM IMPORTANT: Reprogram the body control module (BCM) with the proper RPO configurations before you perform the learn procedures. When you replace the BCM, the module will learn PASSLOCK Sensor Data Code immediately. However, the existing PCM must learn the new fuel continue password. When you replace a PCM, after programming, these modules will learn the incoming fuel continue password immediately upon receipt of a password message. Once a password message is received, and a password is learned, perform the learn procedure again if you want to change this password. A PCM which was previously installed in another vehicle will have learned the other vehicle's fuel continue password, and will require a learn procedure after programming in order to learn the current vehicle's password. Always use GM Service Parts Operations (SPO) Replacement Parts. 10 Minute Re-Learn Procedure Use this procedure after replacing any of the following components: 1. Lock Cylinders/PASSLOCK Sensors 2. BCM 3. PCM Tech 2 Programming Procedure Use the following procedures in order to program the BCM with the Tech 2 equipment. 1. Connect the Tech 2 Diagnostic tool. 2. Select Request Information under Service Programming. 3. Disconnect the Tech 2 from the vehicle and connect it to a Techline Terminal. 4. On the Techline Terminal, select Theft Module Re-Learn under Service Programming. 5. Disconnect the Tech 2 from the Techline Terminal and connect the Tech 2 to the vehicle. 6. Turn ON the ignition, with the engine OFF. 7. Select VTD Re-Learn under Service Programming. 8. At this point you may disconnect the Tech 2, the Tech 2 is no longer required. 9. Observe the Security telltale, after approximately 10 minutes the telltale will turn OFF. The vehicle is now ready to relearn the PASSLOCK Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. 10. Turn OFF the ignition, and wait 5 seconds. 11. Start the engine. (The vehicle has now learned keys). 12. Using a scan tool, clear any DTCs. 30 Minute Re-Learn Procedure Use this procedure after replacing lock cylinders, PASSLOCK Module/BCM or the PCM (if necessary - see note above). 1. Turn ON the ignition, with the engine OFF. 2. Attempt to start the engine, then release the key to ON (The vehicle will not start). 3. Observe the Security telltale, after approximately 10 minutes the telltale will turn OFF. 4. Turn OFF the ignition, and wait 5 seconds. 5. Repeat steps 1-4 two more times, for a total of 3 cycles and 30 minutes. The vehicle is now ready to relearn the PASSLOCK Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. IMPORTANT: The vehicle learns the PASSLOCK Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK. You must turn the ignition OFF before attempting to start the vehicle. 6. Start the engine. (The vehicle has now learned the PASSLOCK Sensor Data Code and/or password.) 7. Using a scan tool, clear any DTCs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Service and Repair > Antenna Module Replacement Antenna Control Module: Service and Repair Antenna Module Replacement Antenna Module Replacement REMOVAL PROCEDURE 1. Remove the LH rear quarter upper trim panel. 2. Disconnect the antenna amplifier electrical connector and the antenna coaxial cable. The antenna coaxial cable uses a sliding snap-lock. Pull the lock in order to remove the antenna coaxial cable. 3. Detach the black antenna leads from the glass. The upper lead is held to the body metal with a wiring clip. Carefully pry the clip out of the metal. 4. Remove the antenna amplifier bolt. 5. Remove the antenna amplifier. INSTALLATION PROCEDURE 1. Position the antenna amplifier to the LH rear window inner upper panel. Install the antenna amplifier bolt. Tighten Tighten the antenna amplifier bolt to 3 N.m (27 lb in). IMPORTANT: The antenna coaxial cable uses a sliding snap-lock. Holding the sliding lock feature will prevent installation. 2. Connect the antenna amplifier electrical connectors: 2.1. Position the antenna coaxial cable behind the sliding lock feature. 2.2. Install the antenna coaxial cable to the sliding lock feature. IMPORTANT: If the wiring clip is faulty, the wiring clip must be replaced prior to installation. 3. Install the antenna leads to the rear window terminals. Push the wiring clip on the upper lead into the hex hole in the metal. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Service and Repair > Antenna Module Replacement > Page 11017 Antenna Control Module: Service and Repair Coaxial Cable Replacement REMOVAL PROCEDURE 1. Loosen the rear of the headliner in order to gain access. 2. Remove the antenna coaxial cable from the radio antenna module. 3. Remove the rear seat cushion. Refer to Seat Cushion Replacement - Rear in Seats. 4. Remove the rear seat back. 5. Remove the left carpet retainers. 6. Remove the lower center pillar trim panel. 7. Adjust the carpet for access to the wiring harness as required. 8. Remove the left instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Service and Repair > Antenna Module Replacement > Page 11018 9. Adjust the radio for access. Disconnect the antenna coaxial cable from the rear of the radio. Refer to Radio Replacement. 10. Cut off the visible end of the coaxial antenna cable from the wiring harness in the kick panel area. 11. Cut off the visible end of the coaxial antenna cable from the wiring harness in the rear shelf area. INSTALLATION PROCEDURE 1. Install the coaxial antenna cables to the vehicle. Use electrical tape in order to secure the antenna extension cable to the top of the wiring harness. Make sure that the cable is secured to the harness at least every 150 mm (6 in). 2. Connect the coaxial antenna cable to the rear of the radio. Install the radio. IMPORTANT: The antenna coaxial cable uses a sliding snap-lock. Holding the sliding lock feature will prevent installation. 3. Connect the coaxial antenna cable from the radio to the coaxial antenna cable near the kick panel: 3.1. Position the antenna coaxial cable behind the sliding lock feature. 3.2. Install the antenna coaxial cable to the sliding lock feature. 4. Install the left instrument panel insulator. 5. Install the carpet. 6. Install the lower center pillar trim panel. 7. Install the left carpet retainers. 8. Connect the coaxial antenna cable from the body wiring harness to the coaxial antenna cable at the rear shelf area. 9. Install the rear seat back. 10. Install the rear seat cushion. IMPORTANT: The antenna coaxial cable uses a sliding snap-lock. Holding the sliding lock feature will prevent installation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Service and Repair > Antenna Module Replacement > Page 11019 11. Connect the antenna coaxial cable to the radio antenna module. 11.1. Position the antenna coaxial cable behind the sliding lock feature. 11.2. Install the antenna coaxial cable to the sliding lock feature. 12. Install the rear of the headliner. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11028 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11029 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11030 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11031 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11032 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11033 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11034 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11035 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11036 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11037 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11038 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11039 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11040 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11041 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11042 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11043 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11044 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11045 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11046 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11047 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11048 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11049 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11050 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11051 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11052 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11053 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11054 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11055 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11056 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11057 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11058 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11059 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11060 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11061 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 11067 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 11072 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 11078 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11083 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11084 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11085 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11086 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11087 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11088 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11089 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11090 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11091 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11092 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11093 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11094 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11095 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11096 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11097 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11098 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11099 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11100 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11101 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11102 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11103 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11104 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11105 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11106 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11107 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11108 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11109 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11110 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11111 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11112 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11113 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11114 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11115 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11116 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-64-007A > Sep > 08 > OnStar(R) - Analog Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 11133 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-007 > Dec > 06 > OnStar - Analog-Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar - Analog-Only Systems Information Bulletin No.: 06-08-46-007 Date: December 13, 2006 INFORMATION Subject: Information on OnStar(R) Analog-Only Systems Models: 1996-2001 GM Passenger Cars and Trucks Plus: 2002 Buick LeSabre, Rendezvous 2002-2003 Buick Century, Regal 2002-2005 Buick Park Avenue 2002 Cadillac Eldorado, Escalade Models 2002 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Venture 2002 GMC Denali, Denali XL, Jimmy, Sierra, Yukon, Yukon XL 2002 Oldsmobile Intrigue, Silhouette 2002-2003 Oldsmobile Aurora 2002 Pontiac Aztek, Bonneville, Montana 2002-2003 Pontiac Grand Prix with OnStar(R) (RPO UE1) All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog/Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 11143 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-64-007A > Sep > 08 > OnStar(R) - Analog Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 11160 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-007 > Dec > 06 > OnStar - Analog-Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar - Analog-Only Systems Information Bulletin No.: 06-08-46-007 Date: December 13, 2006 INFORMATION Subject: Information on OnStar(R) Analog-Only Systems Models: 1996-2001 GM Passenger Cars and Trucks Plus: 2002 Buick LeSabre, Rendezvous 2002-2003 Buick Century, Regal 2002-2005 Buick Park Avenue 2002 Cadillac Eldorado, Escalade Models 2002 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Venture 2002 GMC Denali, Denali XL, Jimmy, Sierra, Yukon, Yukon XL 2002 Oldsmobile Intrigue, Silhouette 2002-2003 Oldsmobile Aurora 2002 Pontiac Aztek, Bonneville, Montana 2002-2003 Pontiac Grand Prix with OnStar(R) (RPO UE1) All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog/Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11170 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11171 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11172 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11173 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11174 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11175 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11176 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11177 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11178 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11179 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11180 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11181 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11182 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11183 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11184 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11185 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11186 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11187 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11188 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11189 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11190 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11191 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11192 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11193 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11194 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11195 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11196 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11197 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11198 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11199 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11200 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11201 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11202 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11203 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11228 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11229 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11230 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11236 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11237 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11238 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11247 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11248 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11249 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 11255 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 11256 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 11257 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 11262 Passlock(TM) Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Body Control Module: Customer Interest BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 11277 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 Body Control Module: Customer Interest Body Control Module - MIL ON/DTCs B2647/B2648 File In Section: 08 - Body and Accessories Bulletin No.: 00-08-47-002 Date: September, 2000 Subject: Service Vehicle Soon (SVS) Message, DTC B2647 and/or B2648 Set (Replace Body Control Module) Models: 2000 Chevrolet Impala, Monte Carlo Built Prior to VIN Breakpoint Y9255551 Condition Some customers may comment about a "Service Vehicle Soon" message displayed, which may or may not store diagnostic codes (DTCs) B2647 and/or B2648. Cause The headlamp auto control ambient light sensor sends a brief voltage spike to the body control module (BCM) during engine crank, which may be detected as a fault by the BCM. This may initiate the SVS message. This voltage is considered a normal condition of the ambient light sensor. Correction Replace the body control module (BCM) to correct this condition. BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: ^ The vehicle will not be protected against theft by the Passlock(TM) system. ^ The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 11282 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (* )You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 11283 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 47. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 48. Select Set Options and press Enter. 49. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 50. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 51. Select Set Option Configuration and press Enter. 52. Press the key under the highlighted Done area of the Tech 2 display. 53. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 54. Exit back to the Main Menu screen. 55. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 56. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 57. Turn the ignition switch to OFF and wait 15 seconds. 58. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 59. The Security and Battery messages will begin toggling. 60. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 61. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 11284 62. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 63. The Security and Battery messages will begin toggling. 64. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 65. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 66. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 67. The Security and Battery messages will begin toggling. 68. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 69. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 70. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Parts Information The BCM part number has not changed, but the new BCM should have a code GMAB139 or higher on the label. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Body Control Module: All Technical Service Bulletins BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 11290 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-52-001 > Feb > 04 > Keyless Entry - BCM Set-Up Programming Body Control Module: All Technical Service Bulletins Keyless Entry - BCM Set-Up Programming Bulletin No.: 04-08-52-001 Date: February 25, 2004 INFORMATION Subject: Set-up/Programming BCM for Remote Keyless Entry (RKE) Models: 2000-2004 Chevrolet Impala, Monte Carlo In the past, when replacing the BCM on the above listed vehicles, the module had to be set-up to ensure the RKE was initiated. The RKE option RPO may not have been called out individually on the SPID label when the RKE option was part of an option package. This would often lead to this option being missed during BCM set-up and leading to an inoperative RKE feature. The new BCM, P/N 10350647, currently available, will automatically toggle the RKE function on during initiation of the module. Therefore, it is no longer necessary to turn on the RKE. Just leave it on regardless if the vehicle is equipped with RKE or not. This will prevent an incorrect set-up causing this feature to become inoperative. This new BCM will also remedy a situation where some older BCMs would not remember the horn chirp setting, short or long, after going into sleep mode. Also, this new BCM will not lock the settings until after 32 key cycles compared to 15 key cycles on older BCMs. So, if a mistake is made during the initial set-up, you can re-set the module. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 Body Control Module: All Technical Service Bulletins Body Control Module - MIL ON/DTCs B2647/B2648 File In Section: 08 - Body and Accessories Bulletin No.: 00-08-47-002 Date: September, 2000 Subject: Service Vehicle Soon (SVS) Message, DTC B2647 and/or B2648 Set (Replace Body Control Module) Models: 2000 Chevrolet Impala, Monte Carlo Built Prior to VIN Breakpoint Y9255551 Condition Some customers may comment about a "Service Vehicle Soon" message displayed, which may or may not store diagnostic codes (DTCs) B2647 and/or B2648. Cause The headlamp auto control ambient light sensor sends a brief voltage spike to the body control module (BCM) during engine crank, which may be detected as a fault by the BCM. This may initiate the SVS message. This voltage is considered a normal condition of the ambient light sensor. Correction Replace the body control module (BCM) to correct this condition. BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: ^ The vehicle will not be protected against theft by the Passlock(TM) system. ^ The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 11299 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (* )You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 11300 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 47. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 48. Select Set Options and press Enter. 49. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 50. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 51. Select Set Option Configuration and press Enter. 52. Press the key under the highlighted Done area of the Tech 2 display. 53. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 54. Exit back to the Main Menu screen. 55. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 56. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 57. Turn the ignition switch to OFF and wait 15 seconds. 58. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 59. The Security and Battery messages will begin toggling. 60. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 61. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 00-08-47-002 > Sep > 00 > Body Control Module - MIL ON/DTCs B2647/B2648 > Page 11301 62. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 63. The Security and Battery messages will begin toggling. 64. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 65. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 66. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 67. The Security and Battery messages will begin toggling. 68. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 69. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 70. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Parts Information The BCM part number has not changed, but the new BCM should have a code GMAB139 or higher on the label. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure Body Control Module: All Technical Service Bulletins BCM - Related Service, Theft Deterrent Relearn Procedure File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-057A Date: May, 2000 INFORMATION Subject: Body Control Module (BCM) Related Service, Theft Deterrent Re-Learn Procedure Models: 2000 Chevrolet Impala, Monte Carlo This bulletin is being revised to update the service procedure and the labor time information. Please discard Corporate Bulletin Number 99-06-O4-057 (Section 6 - Engine/Propulsion System). BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: - The vehicle will not be protected against theft by the Passlock(TM) system. - The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 11306 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (*) You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 11307 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. 47. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 48. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 49. Select Set Options and press Enter. 50. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 51. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 52. Select Set Option Configuration and press Enter. 53. Press the key under the highlighted Done area of the Tech 2 display. 54. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 55. Exit back to the Main Menu screen. 56. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 57. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 58. Turn the ignition switch to OFF and wait 15 seconds. 59. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 60. The Security and Battery messages will begin toggling. 61. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 62. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 63. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 64. The Security and Battery messages will begin toggling. 65. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 66. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 67. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM - Related Service, Theft Deterrent Relearn Procedure > Page 11308 release the ignition switch to the RUN position (the engine will not crank). 68. The Security and Battery messages will begin toggling. 69. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 70. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 71. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N4800 Computer (Control), Body - 1.1 hrs Replace and Program Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn Body Control Module: All Technical Service Bulletins BCM - Related Service. Theft Deterrent Relearn File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-057 Date: November, 1999 INFORMATION Subject: Body Control Module (BCM) Related Service, Theft Deterrent Re-Learn Procedure Models: 2000 Chevrolet Impala, Monte Carlo BCM replacement requires that a programming function be performed. If the BCM is not properly programmed, the vehicle may not start because the Theft Lock System will be enabled. Important: If the module is not properly programmed within twenty (20) key cycles (including the VIN), the module will lock and programming will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reprogrammed. When replacing the BCM, a critical component of the procedure requires a programming of the BCM. To program the BCM, follow all of the steps in the procedure listed. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "setup new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: - The vehicle will not be protected against theft by the Passlock(TM) system. - The engine will not crank or start. Programming of the BCM requires the use of the Tech 2 scan tool. 1. Insure that the key (or ignition) switch is in the LOCK position with the ignition off. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the key to the ON position. 4. The following items all refer to the Tech 2 scan tool inputs: ^ Select Diagnostics and answer the questions when prompted by the Tech 2. ^ Select Body Control Module (BCM). ^ Select Special Functions. ^ Select New VIN and input the required data. ^ Exit back to the Special Functions menu. 5. Select BCM Programming. 6. Press the YES key when the following message is displayed: Do you want to setup a body control module? 7. The Tech 2 will then display the following message: Now setting up the New Body Control Module. 8. When the BCM has been setup successfully, the Tech 2 will display this message: Body Control Module setup is complete. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 11313 THIS MEANS THAT THE TECH 2 HAS SET THE BCM TO ACCEPT THE CORRECT INFORMATION. THIS IS NOT THE END OF THE PROGRAMMING PROCEDURE. 9. Exit back to the Special Functions menu. 10. Select Set Options. 11. Input all of the required data as prompted by the Tech 2. 12. Exit back to the Special Functions menu. 13. Select Option Configuration. 14. Input all of the required data as prompted by the Tech 2. 15. When the BCM, VIN, Point of Sale and option configuration have been entered, proceed with the Theft Deterrent Re-Learn Procedure. IF THE TECH 2 DISPLAYS "UNABLE TO PROGRAM THE BCM", THE BCM IS LOCKED. TWENTY KEY CYCLES HAVE OCCURRED SINCE THE MODULE WAS INSTALLED AND VOLTAGE WAS SUPPLIED TO THE MODULE SO THE MODULE MUST BE REPLACED AND THIS PROCEDURE MUST BE REPEATED IN ITS ENTIRETY. Important: Programming of the BCM removes any personalization settings the customer may have previously set. Inform the customer the personalization settings will have to be reset. Theft Deterrent Re-Learn Important: Perform the Theft Deterrent Re-Learn Procedure when one or more of the following conditions has occurred. - The BCM has been replaced or re-programmed (Set-up) (Configured). - The ignition key cylinder assembly has been replaced. The Theft Deterrent Re-Learn Procedure can be accomplished two different ways depending on the equipment you have available. ^ Using The Techline equipment and the Tech 2 scan tool. ^ Without Techline Equipment of any kind. This procedure takes 30 minutes and must not be shortened. USING TECHLINE EQUIPMENT AND THE TECH 2 SCAN TOOL 1. If you disconnected the scan tool from the DLC, perform the following 3 steps. If it is still connected, proceed to step 5. 2. Ensure that the key (or ignition) switch is in the LOCK position with the ignition off. 3. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 4. Turn the key to the ON position. 5. From the Main Menu screen of the Tech 2, select Service Programming. 6. Enter the requested information. 7. Select Request Info. 8. When the Tech 2 finishes gathering the information, disconnect the Tech 2 from the DLC. 9. Connect the Tech 2 to the Techline terminal. 10. Select Service Programming System (SPS). 11 Select Terminal to Tech 2 programming. 12. Select Done. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 11314 13. Follow the instructions displayed on the Techline terminal for hand-held communications set-up screen. 14. Select Theft Module Re-Learn. 15. Select program at the summary screen. The terminal will now download information into the Tech 2. 16. Disconnect the Tech 2 from the Techline terminal. 17. Re-connect the Tech 2 to the DLC. 18. At the Scan Tool Main Menu, select Service Programming. 19. Answer the Tech 2 question. 20. Select Re-Learn. 21. The PCM and BCM are now prepared for the Re-Learn procedure to begin. 22. An internal security timer will now start. The security timer is 10 minutes in duration. Important: During this 10 minute period, the scan tool must NOT be disconnected from the vehicle. Does the Tech 2 display any kind of message telling you to proceed? 23. Turn the ignition switch to the OFF position. 24. Start the engine. The engine should start and continue to run. 25. The Theft Re-Learn procedure is complete. Look for any DTCs which may have been set during this procedure. If codes were set, clear them now. Remove the Tech 2 from the vehicle. WITHOUT TECHLINE EQUIPMENT OF ANY KIND This procedure takes 30 minutes and must not be shortened. 1. Ensure that the battery is fully charged before starting this procedure. 2. Turn the ignition switch to the OFF position. 3. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 4. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 5. Turn the ignition switch to the OFF position for 5 seconds. 6. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 7. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 8. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 9. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 10. Turn the ignition switch to the OFF position for 5 seconds. 11. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will now start. 12. Using the Tech 2, look for a Clear All Trouble Codes (DTCs). Warranty Information For vehicles repaired under warranty, use: Operation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM - Related Service. Theft Deterrent Relearn > Page 11315 Labor Description Labor Time N4800 Computer (Control), Body - 0.7 hr Replace and Program Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 04-08-52-001 > Feb > 04 > Keyless Entry - BCM Set-Up Programming Body Control Module: All Technical Service Bulletins Keyless Entry - BCM Set-Up Programming Bulletin No.: 04-08-52-001 Date: February 25, 2004 INFORMATION Subject: Set-up/Programming BCM for Remote Keyless Entry (RKE) Models: 2000-2004 Chevrolet Impala, Monte Carlo In the past, when replacing the BCM on the above listed vehicles, the module had to be set-up to ensure the RKE was initiated. The RKE option RPO may not have been called out individually on the SPID label when the RKE option was part of an option package. This would often lead to this option being missed during BCM set-up and leading to an inoperative RKE feature. The new BCM, P/N 10350647, currently available, will automatically toggle the RKE function on during initiation of the module. Therefore, it is no longer necessary to turn on the RKE. Just leave it on regardless if the vehicle is equipped with RKE or not. This will prevent an incorrect set-up causing this feature to become inoperative. This new BCM will also remedy a situation where some older BCMs would not remember the horn chirp setting, short or long, after going into sleep mode. Also, this new BCM will not lock the settings until after 32 key cycles compared to 15 key cycles on older BCMs. So, if a mistake is made during the initial set-up, you can re-set the module. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM Related Service, Theft Deterrent Relearn Procedure Body Control Module: All Technical Service Bulletins BCM - Related Service, Theft Deterrent Relearn Procedure File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-057A Date: May, 2000 INFORMATION Subject: Body Control Module (BCM) Related Service, Theft Deterrent Re-Learn Procedure Models: 2000 Chevrolet Impala, Monte Carlo This bulletin is being revised to update the service procedure and the labor time information. Please discard Corporate Bulletin Number 99-06-O4-057 (Section 6 - Engine/Propulsion System). BCM replacement is not complete until the BCM is configured to the vehicle and the vehicle theft deterrent re-learn is completed. Without BCM configuration, the radio will display locked (Theft Lock Enabled) and the vehicle's engine will not crank (Vehicle Theft Deterrent Enabled). The radio theft lock system compares the VIN in the BCM with the VIN in the radio. If the VIN was not entered in the BCM at the time of replacement/configuration, the radio will display "Locked". If the vehicle theft deterrent procedure is not completed properly, the engine will not crank when the key is turned to the crank position. Important: If the module is not properly configured within twenty (20) key cycles (including the VIN), the module will lock and configuring will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reconfigured. When replacing the BCM, a critical component of the procedure requires a configuring of the BCM. To configure the BCM, follow all of the steps in the procedure listed below. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "set-up new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: - The vehicle will not be protected against theft by the Passlock(TM) system. - The engine will not crank or start. Configuring of the BCM requires the use of the Tech 2 scan tool. Ensure that the Tech 2 has been updated. Begin the service procedure with the original BCM in the vehicle. 1. Set the parking brake. This will keep the headlamps and/or the daytime running lamps OFF. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the ignition key to the ON/RUN position. Do not start the engine. 4. Press the Power key on the Tech 2. 5. Press the Enter key on the Tech 2. 6. Select Diagnostics and press Enter. 7. Select Model Year 2000 and press Enter. 8. Select Passenger Car and press Enter. 9. Select Body and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM Related Service, Theft Deterrent Relearn Procedure > Page 11325 10. Select W as the Car Product Line and press Enter. 11. Select Chevrolet and press Enter. 12. Select the proper vehicle and press Enter. 13. Select Body Control Module and press Enter. 14. Select Special Functions and press Enter. 15. Select Set Options and press Enter. 16. Select Set Option Configuration and press Enter. 17. Press the key under the highlighted Done area of the Tech 2 display. 18. The setting option screen will display the options currently set in this vehicle. Record the Tech 2 display of the special options highlighted with an asterisk (*) You will need to re-enter this information in a later step. 19. Press the key under the highlighted Save Options area on the Tech 2 screen. A Loss of Communications message will display on the Tech 2 (ignore this message). 20. Press Exit. 21. Turn the ignition key to the OFF position. 22. Disconnect the Tech 2 from the vehicle's DLC. 23. Remove the LH sound insulator panel located under the dash. 24. Disconnect the three BCM wiring connectors. 25. Remove the BCM from the vehicle. 26. Install the new BCM in the vehicle. 27. Connect the three wiring harness connectors to the BCM. 28. Install the LH sound insulator panel. 29. Connect the Tech 2 scan tool to the DLC. 30. Turn the ignition key to the ON/RUN position. 31. Press the Power key on the Tech 2. 32. Press the Enter key on the Tech 2. 33. Select Diagnostics and press Enter. 34. Select Model Year 2000 and press Enter. 35. Select Passenger Car and press Enter. 36. Select Body and press Enter. 37. Select W as the Car Product Line and press Enter. 38. Select Chevrolet and press Enter. 39. Select the proper vehicle and press Enter. 40. Select Body Control Module and press Enter. 41. Select Special Functions and press Enter. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM Related Service, Theft Deterrent Relearn Procedure > Page 11326 42. Select New VIN and press Enter. 43. Enter the correct VIN. 44. Press Exit until you are back to the Special Functions screen. 45. Select BCM Programming and press Enter. 46. Select Set-Up BCM. Press the key under the highlighted Set-Up BCM on the Tech 2. 47. The Tech 2 will display the following message: NOW SETTING UP THE NEW BODY CONTROL MODULE. 48. A Body Control Setup Complete message will appear on the display. Press the key under the highlighted Exit. 49. Select Set Options and press Enter. 50. Select Point of Sale and press Enter. The setting options screen will appear again. Press the key under the highlighted Done again. 51. Select Domestic under Point of Sale. Press the key under the Save option area on the screen. 52. Select Set Option Configuration and press Enter. 53. Press the key under the highlighted Done area of the Tech 2 display. 54. Select the options you recorded from the original BCM in Step 18. Highlight the option by using the arrow keys on the Tech 2. Press Enter to place an asterisk (*) in front of the option. When all the options have been selected, press the key under the highlighted Save Options area on the Tech 2. 55. Exit back to the Main Menu screen. 56. Remove the Tech 2 from the DLC and the vehicle. Important: Perform the following theft deterrent re-learn procedure when one or more of the following conditions has occurred: ^ The BCM has been replaced or reprogrammed (set-up, configured). ^ The ignition key cylinder assembly has been replaced. 57. You MUST perform the following manual theft deterrent re-learn procedure. The required procedure has a special step that must be completed or the theft re-learn will not work. 58. Turn the ignition switch to OFF and wait 15 seconds. 59. Turn the ignition switch to START. Hold it in this position until the instrument cluster telltale lamps illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 60. The Security and Battery messages will begin toggling. 61. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 62. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 63. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then release the ignition switch to the RUN position (the engine will not crank). 64. The Security and Battery messages will begin toggling. 65. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 66. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 67. Turn the ignition switch to START and hold it in this position until the instrument cluster telltales illuminate (approximately seven seconds). Then Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057A > May > 00 > BCM Related Service, Theft Deterrent Relearn Procedure > Page 11327 release the ignition switch to the RUN position (the engine will not crank). 68. The Security and Battery messages will begin toggling. 69. The ignition key must NOT be disturbed for the next 10 minutes. When the 10 minute time period has elapsed, the Security/Battery telltale will become a solid battery-only lamp. 70. Turn the ignition to OFF. With the PRNDL display off, wait five seconds. 71. Turn the ignition switch to ON and wait 15 seconds before starting the engine. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N4800 Computer (Control), Body - 1.1 hrs Replace and Program Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM Related Service. Theft Deterrent Relearn Body Control Module: All Technical Service Bulletins BCM - Related Service. Theft Deterrent Relearn File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-057 Date: November, 1999 INFORMATION Subject: Body Control Module (BCM) Related Service, Theft Deterrent Re-Learn Procedure Models: 2000 Chevrolet Impala, Monte Carlo BCM replacement requires that a programming function be performed. If the BCM is not properly programmed, the vehicle may not start because the Theft Lock System will be enabled. Important: If the module is not properly programmed within twenty (20) key cycles (including the VIN), the module will lock and programming will not be allowed. For this reason, replacing the module with a module from another vehicle will not work. They cannot be reprogrammed. When replacing the BCM, a critical component of the procedure requires a programming of the BCM. To program the BCM, follow all of the steps in the procedure listed. Important: Before starting this procedure, read through it carefully and completely. The BCM will not function properly if the "setup new" BCM procedure is not performed correctly. Also, perform the theft deterrent re-learn procedure. If this is not performed, the following conditions will occur: - The vehicle will not be protected against theft by the Passlock(TM) system. - The engine will not crank or start. Programming of the BCM requires the use of the Tech 2 scan tool. 1. Insure that the key (or ignition) switch is in the LOCK position with the ignition off. 2. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 3. Turn the key to the ON position. 4. The following items all refer to the Tech 2 scan tool inputs: ^ Select Diagnostics and answer the questions when prompted by the Tech 2. ^ Select Body Control Module (BCM). ^ Select Special Functions. ^ Select New VIN and input the required data. ^ Exit back to the Special Functions menu. 5. Select BCM Programming. 6. Press the YES key when the following message is displayed: Do you want to setup a body control module? 7. The Tech 2 will then display the following message: Now setting up the New Body Control Module. 8. When the BCM has been setup successfully, the Tech 2 will display this message: Body Control Module setup is complete. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM Related Service. Theft Deterrent Relearn > Page 11332 THIS MEANS THAT THE TECH 2 HAS SET THE BCM TO ACCEPT THE CORRECT INFORMATION. THIS IS NOT THE END OF THE PROGRAMMING PROCEDURE. 9. Exit back to the Special Functions menu. 10. Select Set Options. 11. Input all of the required data as prompted by the Tech 2. 12. Exit back to the Special Functions menu. 13. Select Option Configuration. 14. Input all of the required data as prompted by the Tech 2. 15. When the BCM, VIN, Point of Sale and option configuration have been entered, proceed with the Theft Deterrent Re-Learn Procedure. IF THE TECH 2 DISPLAYS "UNABLE TO PROGRAM THE BCM", THE BCM IS LOCKED. TWENTY KEY CYCLES HAVE OCCURRED SINCE THE MODULE WAS INSTALLED AND VOLTAGE WAS SUPPLIED TO THE MODULE SO THE MODULE MUST BE REPLACED AND THIS PROCEDURE MUST BE REPEATED IN ITS ENTIRETY. Important: Programming of the BCM removes any personalization settings the customer may have previously set. Inform the customer the personalization settings will have to be reset. Theft Deterrent Re-Learn Important: Perform the Theft Deterrent Re-Learn Procedure when one or more of the following conditions has occurred. - The BCM has been replaced or re-programmed (Set-up) (Configured). - The ignition key cylinder assembly has been replaced. The Theft Deterrent Re-Learn Procedure can be accomplished two different ways depending on the equipment you have available. ^ Using The Techline equipment and the Tech 2 scan tool. ^ Without Techline Equipment of any kind. This procedure takes 30 minutes and must not be shortened. USING TECHLINE EQUIPMENT AND THE TECH 2 SCAN TOOL 1. If you disconnected the scan tool from the DLC, perform the following 3 steps. If it is still connected, proceed to step 5. 2. Ensure that the key (or ignition) switch is in the LOCK position with the ignition off. 3. Connect the Tech 2 scan tool to the Data Link Connector (DLC). 4. Turn the key to the ON position. 5. From the Main Menu screen of the Tech 2, select Service Programming. 6. Enter the requested information. 7. Select Request Info. 8. When the Tech 2 finishes gathering the information, disconnect the Tech 2 from the DLC. 9. Connect the Tech 2 to the Techline terminal. 10. Select Service Programming System (SPS). 11 Select Terminal to Tech 2 programming. 12. Select Done. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM Related Service. Theft Deterrent Relearn > Page 11333 13. Follow the instructions displayed on the Techline terminal for hand-held communications set-up screen. 14. Select Theft Module Re-Learn. 15. Select program at the summary screen. The terminal will now download information into the Tech 2. 16. Disconnect the Tech 2 from the Techline terminal. 17. Re-connect the Tech 2 to the DLC. 18. At the Scan Tool Main Menu, select Service Programming. 19. Answer the Tech 2 question. 20. Select Re-Learn. 21. The PCM and BCM are now prepared for the Re-Learn procedure to begin. 22. An internal security timer will now start. The security timer is 10 minutes in duration. Important: During this 10 minute period, the scan tool must NOT be disconnected from the vehicle. Does the Tech 2 display any kind of message telling you to proceed? 23. Turn the ignition switch to the OFF position. 24. Start the engine. The engine should start and continue to run. 25. The Theft Re-Learn procedure is complete. Look for any DTCs which may have been set during this procedure. If codes were set, clear them now. Remove the Tech 2 from the vehicle. WITHOUT TECHLINE EQUIPMENT OF ANY KIND This procedure takes 30 minutes and must not be shortened. 1. Ensure that the battery is fully charged before starting this procedure. 2. Turn the ignition switch to the OFF position. 3. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 4. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 5. Turn the ignition switch to the OFF position for 5 seconds. 6. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 7. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 8. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will not start. 9. The security light will come on and stay on for approximately 10 minutes. When the security light goes out, proceed to the next step. 10. Turn the ignition switch to the OFF position for 5 seconds. 11. Rotate the ignition switch all the way to the START position then back to the RUN position. The engine will now start. 12. Using the Tech 2, look for a Clear All Trouble Codes (DTCs). Warranty Information For vehicles repaired under warranty, use: Operation Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 99-06-04-057 > Nov > 99 > BCM Related Service. Theft Deterrent Relearn > Page 11334 Labor Description Labor Time N4800 Computer (Control), Body - 0.7 hr Replace and Program Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Component Locations Body Control Module: Component Locations Locations View LH side of the instrument panel, above parking brake. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 11337 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11340 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11341 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11342 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11343 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11344 Body Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11345 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11346 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11347 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11348 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11349 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11350 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11351 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11352 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11353 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11354 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11355 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11356 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11357 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11358 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11359 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11360 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11361 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11362 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11363 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11364 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11365 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11366 Body Control Module: Connector Views Body Control Module, C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11367 Body Control Module, C2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11368 Body Control Module, C3 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11369 Body Control Module: Electrical Diagrams Body Control Module Schematics: Door Lock Switches, LH Front Door Lock Assembly Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11370 Body Control Module Schematics: DRL Relay, Backup Relay And Ambient Light Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11371 Body Control Module Schematics: Headlamp Switch, Ignition Key Alarm Switch, Surveillance Switch And Park Brake Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11372 Body Control Module Schematics: Headlamp Dimmer Switch, Headlamp Relay, Parklamp Relay Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11373 Body Control Module Schematics: HORN Relay FOG LP Relay And Fog Lamp Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11374 Body Control Module Schematics: Interior Lights (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11375 Body Control Module Schematics: Interior Lights (Part 2 of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11376 Body Control Module Schematics: Power, Grounds and RAP Relay Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11377 Body Control Module Schematics: Brake Transaxle Shift Interlock Control, Rear Compartment Lid Release And Remote Control Door Lock Receiver Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11378 Body Control Schematics: Rear Defog Relay, Door Lock Cylinder Switches Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11379 Body Control Module Schematics: RF And Rear Door Lock Assemblys Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11380 Body Control Module Schematics: SEO Rear Compartment Lid Relay Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11381 Body Control Module Schematics: Traction Control Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description Body Control Module: Description and Operation Circuit Description General Information The Body Control Module (BCM) is capable of accomplishing multiple body control functions. Components directly connected to the BCM are controlled by the BCM's outputs. The BCM can control its outputs based on input information it obtains from sensors and switches that are directly connected to the BCM, or by borrowing information from other vehicle systems connected to the Class 2 serial data link. The BCM evaluates this information and controls certain body systems by commanding an output on or off. The BCM is also capable of commanding other vehicle systems to control functions that are not directly wired and/or controlled by the BCM. The BCM accomplishes this task by sending specific messages on the Class 2 serial data link. The vehicle system capable of performing such function will respond to the BCM message. The BCM performs these functions: ^ Audible warnings. ^ Interior lighting. ^ Automatic door locks. ^ Keyless entry (AUO option) ^ Passlock theft deterrent. ^ Content Theft (UA6 option) ^ Retained Accessory Power (RAP) RPO AUO, UA6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Audible Warnings ^ Key in ignition reminder. ^ Fasten seat belt reminder. ^ Fasten belts indicator control. ^ Parking brake reminder. ^ Turn signal reminder. ^ Low fuel reminder. ^ Headlamps ON reminder. ^ Last door closed locking confirmation. ^ Feature customization. Interior Lighting ^ Interior illumination control. ^ Delayed illumination. ^ Illuminated entry. ^ Exit illumination. ^ Theater dimming. ^ Keyless entry unlock illumination. ^ Inadvertent load (battery rundown) protection. Automatic Door Locks ^ All door unlock. ^ All door lock. ^ Last door closed locking. ^ Lockout prevention. ^ Lockout prevention override. ^ Shift into PARK unlock. ^ Shift out of PARK lock. ^ Remote driver door unlock. ^ Remote all door unlock. ^ Remote all door lock. Keyless Entry ^ Remote driver door unlock. ^ Remote all door unlock. ^ Remote all door lock. ^ Remote activation verification. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 11384 ^ Remote alarm. ^ Feature customization of remote activation verification. BCM Inputs The following components provide direct input to the BCM, plus other systems can use this input information in order to carry out certain functions: ^ A/C Request: Provides the BCM with a request signal to command the A/C compressor through the PCM via Class 2 serial data. ^ BCM Ground: Provides ground for BCM operation. ^ BCM Power: Provides voltage for BCM operation. ^ Courtesy Lights On: Provides the driver the ability to request illumination of the vehicle interior. ^ Crank Signal: Determines when the ignition switch is in the start position. ^ Dome Lamp Switch Input: Determines when the dome lamp switch (Headlamp Switch) is closed to request the dome lamp on. ^ Door Lock Switch: Door lock switch request to lock and unlock the vehicle doors. ^ Door Locks: Provides voltage for door lock actuator operation. ^ Door Open: Provides door ajar status. ^ Driver Door Open: Allows certain chime functions when the driver's door is open. ^ DRL Signal Low: This input provides the BCM with Information through an ambient light sensor for the DRL feature. ^ Exterior Lamps Off: Determines when the headlamp switch is in the OFF position. ^ Fog Lamp Switch input: This input provides the BCM with a request for fog lamps through a momentary switch connected to ground. ^ Headlamp Switch Input: Determines when the Headlamp switch is closed to request the headlamps on. ^ High Beam: Determines the status of the headlamp dimmer switch, so the BCM can send the instrument cluster a message, via Class 2, to turn on the high beam indicator. ^ Ignition 0 Signal: Determines when the ignition switch is in ACCESSORY, ON or START position. ^ Ignition 1 Signal: Determines when the ignition switch is in the ON and START positions. ^ Key In Ignition: Determines when the key is fully inserted in the ignition key cylinder. ^ Key Unlock: Determines the status of the door lock cylinder switches for content theft. ^ Lamp Request: This input requests the BCM to energize the Battery Rundown Protection relay after the car has been turned off and all the doors have been closed, so the interior lights can be turned on. ^ Park Brake Applied: Determines when the parking brake is applied. ^ Park Lamp Switch Input: Determines when the park lamp switch (Headlamp Switch) is closed to request the park lamps on. ^ Passlock Sensor Data: Reads the Passlock sensor security code. ^ Rear Compartment Ajar: Determines if the rear decklid is open or closed. ^ Rear Compartment Release: This input requests the BCM to open the rear compartment lid. ^ RFA Link: Provides an interface allowing the transfer of keyless entry information from the Remote Control Door Lock Receiver (RCDLR). ^ Serial Data: provides an interface with the PCM, EBCM, Radio, SDM, DIC and the IPC through the Class 2 serial data link. ^ Surveillance Switch Input: Determines when the surveillance switch is closed to request the surveillance mode. ^ Traction Control Request: This input provides the BCM with a request for Traction Control through a momentary switch connected to ground. BCM Outputs The BCM directly controls these outputs, plus other systems may request the BCM to control these outputs for certain functions: ^ All Door Lock: This output supplies voltage to the door lock actuators when the doors are commanded to lock. This output also supplies ground to all the door lock actuators when the doors are commanded to unlock. ^ Backup Lamp Relay Control: Provides ground to the Backup LP relay control circuit. ^ BTSI Solenoid Control: Provides ground to the Brake Transaxle Shift Interlock Control Solenoid. ^ Door Unlock: This output supplies voltage to the door lock actuators (except the driver door lock actuator) when the doors are commanded to unlock. This output also supplies ground to all the door lock actuators (except the driver door lock actuator) when the doors are commanded to lock. ^ Driver Door Unlock: This output supplies voltage to the driver door lock actuators when the doors are commanded to unlock. This output also supplies ground to the driver door lock actuator when the doors are commanded to lock. ^ DRL Relay Control: Provides ground to the DRL relay control circuit. ^ DRL 5 V Reference: Provides 5 Volts to the ambient light sensor. ^ Inadvertent Load Relay Control Output: Supplies ground to the battery rundown protection relay providing an inadvertent load (battery rundown) protection. ^ Fog Lamp Enable Control: Sends a ground signal to the fog lamp switch when the ignition switch on; this action enables the fog lamp switch. The fog lamps turn on when the fog lamp switch is enabled by the BCM. ^ Headlamp Relay Control: Provides ground to the Headlamp relay control circuit. ^ Horn: Sends a ground signal to the horn relay, sounding the horn for the keyless entry alarm function or the content theft system. ^ Inadvertent Relay Control: Provides ground to the Battery Rundown Protection relay control circuit. ^ Interior Dimming: Controls the voltage to the interior lights dimming system. ^ Load Management Control: Provides voltage to the Rear Defogger relay control circuit and the Heated Seats. ^ Park Lamp Relay Control: Provides ground to the Park Lamp relay control circuit. ^ Passlock Sensor Power: Provides B+ for Passlock sensor operation. ^ Passlock Sensor Ground: Provides ground to the Passlock sensor. ^ RAP Relay Control: Provides voltage to the RAP relay control feed circuit. ^ Rear Compartment Lid Release Output: Provides ground to Rear Compartment Lid Release Actuator. ^ RFA Link: Provides an interface allowing the transfer of keyless entry information to the Remote Control Door Lock Receiver (RCDLR). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 11385 ^ Serial Data: provides an interface with the PCM, EBCM, Radio, SDM, DIC and the IPC through the Class 2 serial data link. ^ Theater Dimming 1 Control: Supplies ground to activate the Footwell lamps. ^ Theater Dimming 2 Control: Supplies ground to activate the inside rear view mirror lamps, non SEO dome lamp, and the roof rail courtesy/reading lamps. BCM Wake-Up/Sleep State The BCM performs its functions in the wake-up state. The BCM enters the sleep state when active control or monitoring of system malfunctions has stopped, or when the BCM is idling. The BCM must detect certain wake-up inputs before entering the wake-up state. The BCM monitors its inputs during the sleep state, allowing the BCM to switch between the two states, awake or asleep. The BCM enters the wake-up state when receiving activity on any of these inputs: ^ I/P dimmer switch. ^ Door lock (ajar) switch. ^ Door lock switch. ^ A keyless entry system signal. ^ Inadvertent power (battery rundown) protection transition. ^ The ignition is turned to the LOCK, ACCESSORY or the ON position. The sleep state is when the BCM has stopped active control and monitoring of system functions and has become idle again. For the BCM to enter the wake-up state, the BCM must detect a wake-up condition, mentioned previously. These conditions are called wake-up inputs that cause the BCM to change from a sleep to a wake-up state and begin active control and monitoring. The BCM has the ability to monitor for these wake-up inputs in the sleep state. The BCM enters the sleep state when all of these conditions exist: ^ No activity on the Class 2 serial data link. ^ The ignition switch is in the OFF position. ^ The BCM is not commanding any outputs. ^ No delay timers are actively counting (during theft deterrent re-learn). ^ No wake-up inputs are present. Content Theft (UA6 Option) The Body Control Module features a content theft deterrent system which is designed to defer vehicle vandalism and theft. The content theft deterrent system performs these functions: ^ Flashes the headlamps ^ Sounds the horns ^ Disables fuel delivery to the engine The BCM monitors the following: ^ Status of the doors ^ Lock cylinders ^ Rear compartment lid ^ Power door locks ^ The keyless entry system The BCM operates the headlamps, horns and the theft deterrent indicator, thats in the radio, according to the mode of operation the system is in. The BCM also communicates a fuel enable signal to the Powertrain Control Module (PCM) when the system is armed. Refer to Content Theft Deterrent (CTD) Operation in Theft Deterrent for more information. RPO UA6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Miscellaneous Functions ^ BRAKE indicator lamp control: The BCM controls the state of the BRAKE indicator lamp based on the status of the parking brake switch by sending a message to the instrument cluster via the Class 2 serial data link. ^ Fog lamp enable control. The BCM controls fog lamp operation, based on the status of the ignition switch. ^ Day/night mode sensing: The BCM determines the ambient light operating mode. The BCM then communicates the information to the Instrument Cluster and Powertrain Control Module (PCM) via the Class 2 serial data link. Passlock Theft Deterrent The Passlock is a vehicle theft deterrent system. The Passlock theft deterrent system contains a Passlock sensor. The Passlock sensor is part of the ignition lock cylinder assembly. The Body Control Module (BCM) provides power and ground to the Passlock sensor. The Passlock sensor interfaces with the BCM through the Passlock detection circuit. When turning the ignition switch to the start position with the proper key, the Passlock sensor generates an analog voltage signal. This signal is sent through the Passlock detecting circuit. This analog voltage signal is of a specific value to the vehicle, and varies from vehicle to vehicle. When attempting to start the engine, the BCM compares a preset stored analog voltage value with the signal coming from the sensor. Because both values Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 11386 match, the BCM sends a fuel enable password via the Class 2 serial data link to the Powertrain Control Module (PCM). As a result, the PCM enables the crank relay, and allows fuel delivery to the engine. When attempting to start the engine by means other than using the proper key in the ignition switch, the Passlock sensor sends an analog voltage signal of a different value. The BCM compares the preset stored analog voltage value with the signal coming from the sensor. Because both values do not match, the BCM sends a fuel disable password via the Class 2 serial data link to the Powertrain Control Module (PCM). As a result, the PCM disables the crank relay, and does not allow fuel delivery to the engine. Power Requirements The BCM has three main voltage feeds and two grounds. The voltage feed circuits are used to provide power for the BCM's logic, courtesy lights, internal driver operation and the door locks. Retained Accessory Power (RAP) The Accessory Power (RAP) feature allows the operation of the following functions for 10 minutes (or until a vehicle door opens) after the ignition switch has been turned from the ON or ACCESSORY position to the LOCK position: ^ The radio ^ The power windows ^ The power sunroof (if equipped) Refer to Keyless Entry System Operation in Retained Accessory Power (RAP) for more information. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 11387 Body Control Module: Description and Operation System Operation General Information The Body Control Module (BCM) is capable of accomplishing multiple body control functions. Components directly connected to the BCM are controlled by the BCM's outputs. The BCM can control its outputs based on input information it obtains from sensors and switches that are directly connected to the BCM, or by borrowing information from other vehicle systems connected to the Class 2 serial data link. The BCM evaluates this information and controls certain body systems by commanding an output on or off. The BCM is also capable of commanding other vehicle systems to control functions that are not directly wired and/or controlled by the BCM. The BCM accomplishes this task by sending specific messages on the Class 2 serial data link. The vehicle system capable of performing such function will respond to the BCM message. The BCM performs these functions: ^ Audible warnings. ^ Interior lighting. ^ Automatic door locks. ^ Keyless entry (AUO option) ^ Passlock theft deterrent. ^ Content Theft (UA6 option) ^ Retained Accessory Power (RAP) RPO UA6, AUO: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Audible Warnings ^ Key in ignition reminder. ^ Fasten seat belt reminder. ^ Fasten belts indicator control. ^ Parking brake reminder. ^ Turn signal reminder. ^ Low fuel reminder. ^ Headlamps ON reminder. ^ Last door closed locking confirmation. ^ Feature customization. Interior Lighting ^ Interior illumination control. ^ Delayed illumination. ^ Illuminated entry. ^ Exit illumination. ^ Theater dimming. ^ Keyless entry unlock illumination. ^ Inadvertent load (battery rundown) protection. Automatic Door Locks ^ All door unlock. ^ All door lock. ^ Last door closed locking. ^ Lockout prevention. ^ Lockout prevention override. ^ Shift into PARK unlock. ^ Shift out of PARK lock. ^ Remote driver door unlock. ^ Remote all door unlock. ^ Remote all door lock. Keyless Entry ^ Remote driver door unlock. ^ Remote all door unlock. ^ Remote all door lock. ^ Remote activation verification. ^ Remote alarm. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 11388 ^ Feature customization of remote activation verification. BCM Wake-Up/Sleep State The BCM performs its functions in the wake-up state. The BCM enters the sleep state when active control or monitoring of system malfunctions has stopped, or when the BCM is idling. The BCM must detect certain wake-up inputs before entering the wake-up state. The BCM monitors its inputs during the sleep state, allowing the BCM to switch between the two states, awake or asleep. The BCM enters the wake-up state when receiving activity on any of these inputs: ^ I/P dimmer switch. ^ Door lock (ajar) switch. ^ Door lock switch. ^ A keyless entry system signal. ^ Inadvertent power (battery rundown) protection transition. ^ The ignition is turned to the LOCK, ACCESSORY or the ON position. The sleep state is when the BCM has stopped active control and monitoring of system functions and has become idle again. For the BCM to enter the wake-up state, the BCM must detect a wake-up condition, mentioned previously. These conditions are called wake-up inputs that cause the BCM to change from a sleep to a wake-up state and begin active control and monitoring. The BCM has the ability to monitor for these wake-up inputs in the sleep state. The BCM enters the sleep state when all of these conditions exist: ^ No activity on the Class 2 serial data link. ^ The ignition switch is in the OFF position. ^ The BCM is not commanding any outputs. ^ No delay timers are actively counting (during theft deterrent re-learn). ^ No wake-up inputs are present. Content Theft (UA6 Option) The Body Control Module features a content theft deterrent system which is designed to defer vehicle vandalism and theft. The content theft deterrent system performs these functions: ^ Flashes the headlamps ^ Sounds the horns ^ Disables fuel delivery to the engine The BCM monitors the following: ^ Status of the doors ^ Lock cylinders ^ Rear compartment lid ^ Power door locks ^ The keyless entry system The BCM operates the headlamps, horns and the theft deterrent indicator, thats in the radio, according to the mode of operation the system is in. The BCM also communicates a fuel enable signal to the Powertrain Control Module (PCM) when the system is armed. Refer to Content Theft Deterrent (CTD) Operation in Theft Deterrent for more information. RPO UA6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Power Requirements The BCM has three main voltage feeds and two grounds. The voltage feed circuits are used to provide power for the BCM's logic, courtesy lights, internal driver operation and the door locks. BCM Inputs The following components provide direct input to the BCM, plus other systems can use this input information in order to carry out certain functions: ^ A/C Request: Provides the BCM with a request signal to command the A/C compressor through the PCM via Class 2 serial data. ^ BCM Ground: Provides ground for BCM operation. ^ BCM Power: Provides voltage for BCM operation. ^ Courtesy Lights On: Provides the driver the ability to request illumination of the vehicle interior. ^ Crank Signal: Determines when the ignition switch is in the start position. ^ Dome Lamp Switch Input: Determines when the dome lamp switch (Headlamp Switch) is closed to request the dome lamp on. ^ Door Lock Switch: Door lock switch request to lock and unlock the vehicle doors. ^ Door Locks: Provides voltage for door lock actuator operation. ^ Door Open: Provides door ajar status. ^ Driver Door Open: Allows certain chime functions when the driver's door is open. ^ DRL Signal Low: This input provides the BCM with Information through an ambient light sensor for the DRL feature. ^ Exterior Lamps Off: Determines when the headlamp switch is in the OFF position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 11389 ^ Fog Lamp Switch input: This input provides the BCM with a request for fog lamps through a momentary switch connected to ground. ^ Headlamp Switch Input: Determines when the Headlamp switch is closed to request the headlamps on. ^ High Beam: Determines the status of the headlamp dimmer switch, so the BCM can send the instrument cluster a message, via Class 2, to turn on the high beam indicator. ^ Ignition 0 Signal: Determines when the ignition switch is in ACCESSORY, ON or START position. ^ Ignition 1 Signal: Determines when the ignition switch is in the ON and START positions. ^ Key In Ignition: Determines when the key is fully inserted in the ignition key cylinder. ^ Key Unlock: Determines the status of the door lock cylinder switches for content theft. ^ Lamp Request: This input requests the BCM to energize the Battery Rundown Protection relay after the car has been turned off and all the doors have been closed, so the interior lights can be turned on. ^ Park Brake Applied: Determines when the parking brake is applied. ^ Park Lamp Switch Input: Determines when the park lamp switch (Headlamp Switch) is closed to request the park lamps on. ^ Passlock Sensor Data: Reads the Passlock sensor security code. ^ Rear Compartment Ajar: Determines if the rear decklid is open or closed. ^ Rear Compartment Release: This input requests the BCM to open the rear compartment lid. ^ RFA Link: Provides an interface allowing the transfer of keyless entry information from the Remote Control Door Lock Receiver (RCDLR). ^ Serial Data: provides an interface with the PCM, EBCM, Radio, SDM, DIC and the IPC through the Class 2 serial data link. ^ Surveillance Switch Input: Determines when the surveillance switch is closed to request the surveillance mode. ^ Traction Control Request: This input provides the BCM with a request for Traction Control through a momentary switch connected to ground. BCM Outputs The BCM directly controls these outputs, plus other systems may request the BCM to control these outputs for certain functions: ^ All Door Lock: This output supplies voltage to the door lock actuators when the doors are commanded to lock. This output also supplies ground to all the door lock actuators when the doors are commanded to unlock. ^ Backup Lamp Relay Control: Provides ground to the Backup LP relay control circuit. ^ BTSI Solenoid Control: Provides ground to the Brake Transaxle Shift Interlock Control Solenoid. ^ Door Unlock: This output supplies voltage to the door lock actuators (except the driver door lock actuator) when the doors are commanded to unlock. This output also supplies ground to all the door lock actuators (except the driver door lock actuator) when the doors are commanded to lock. ^ Driver Door Unlock: This output supplies voltage to the driver door lock actuators when the doors are commanded to unlock. This output also supplies ground to the driver door lock actuator when the doors are commanded to lock. ^ DRL Relay Control: Provides ground to the DRL relay control circuit. ^ DRL 5 V Reference: Provides 5 Volts to the ambient light sensor. ^ Inadvertent Load Relay Control Output: Supplies ground to the battery rundown protection relay providing an inadvertent load (battery rundown) protection. ^ Fog Lamp Enable Control: Sends a ground signal to the fog lamp switch when the ignition switch on; this action enables the fog lamp switch. The fog lamps turn on when the fog lamp switch is enabled by the BCM. ^ Headlamp Relay Control: Provides ground to the Headlamp relay control circuit. ^ Horn: Sends a ground signal to the horn relay, sounding the horn for the keyless entry alarm function or the content theft system. ^ Inadvertent Relay Control: Provides ground to the Battery Rundown Protection relay control circuit. ^ Interior Dimming: Controls the voltage to the interior lights dimming system. ^ Load Management Control: Provides voltage to the Rear Defogger relay control circuit and the Heated Seats. ^ Park Lamp Relay Control: Provides ground to the Park Lamp relay control circuit. ^ Passlock Sensor Power: Provides B+ for Passlock sensor operation. ^ Passlock Sensor Ground: Provides ground to the Passlock sensor. ^ RAP Relay Control: Provides voltage to the RAP relay control feed circuit. ^ Rear Compartment Lid Release Output: Provides ground to Rear Compartment Lid Release Actuator. ^ RFA Link: Provides an interface allowing the transfer of keyless entry information to the Remote Control Door Lock Receiver (RCDLR). ^ Serial Data: provides an interface with the PCM, EBCM, Radio, SDM, DIC and the IPC through the Class 2 serial data link. ^ Theater Dimming 1 Control: Supplies ground to activate the Footwell lamps. ^ Theater Dimming 2 Control: Supplies ground to activate the inside rear view mirror lamps, non SEO dome lamp, and the roof rail courtesy/reading lamps. Miscellaneous Functions ^ BRAKE indicator lamp control: The BCM controls the state of the BRAKE indicator lamp based on the status of the parking brake switch by sending a message to the instrument cluster via the Class 2 serial data link. ^ Fog lamp enable control. The BCM controls fog lamp operation, based on the status of the ignition switch. ^ Day/night mode sensing: The BCM determines the ambient light operating mode. The BCM then communicates the information to the Instrument Cluster and Powertrain Control Module (PCM) via the Class 2 serial data link. Passlock Theft Deterrent The Passlock is a vehicle theft deterrent system. The Passlock theft deterrent system contains a Passlock sensor. The Passlock sensor is part of the ignition lock cylinder assembly. The Body Control Module (BCM) provides power and ground to the Passlock sensor. The Passlock sensor interfaces with the BCM through the Passlock detection circuit. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Circuit Description > Page 11390 When turning the ignition switch to the start position with the proper key, the Passlock sensor generates an analog voltage signal. This signal is sent through the Passlock detecting circuit. This analog voltage signal is of a specific value to the vehicle, and varies from vehicle to vehicle. When attempting to start the engine, the BCM compares a preset stored analog voltage value with the signal coming from the sensor. Because both values match, the BCM sends a fuel enable password via the Class 2 serial data link to the Powertrain Control Module (PCM). As a result, the PCM enables the crank relay, and allows fuel delivery to the engine. When attempting to start the engine by means other than using the proper key in the ignition switch, the Passlock sensor sends an analog voltage signal of a different value. The BCM compares the preset stored analog voltage value with the signal coming from the sensor. Because both values do not match, the BCM sends a fuel disable password via the Class 2 serial data link to the Powertrain Control Module (PCM). As a result, the PCM disables the crank relay, and does not allow fuel delivery to the engine. Retained Accessory Power (RAP) The Retained Accessory Power (RAP) feature allows the operation of the following functions for 10 minutes (or until a vehicle door opens) after the ignition switch has been turned from the ON or ACCESSORY position to the LOCK position: ^ The radio ^ The power windows ^ The power sunroof (if equipped) Refer to Keyless Entry System Operation in Retained Accessory Power (RAP) for more information. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Body Control Module: Initial Inspection and Diagnostic Overview A Diagnostic Starting Point - Body Control System Begin the diagnosis of the body control system by performing the Diagnostic System Check for the system in which the customer concern is apparent. The Diagnostic System Check will direct you to the correct procedure for diagnosing the system and where the procedure is located. A Diagnostic System Check - Body Control System A Diagnostic System Check-Body Control System TEST DESCRIPTION The number(s) below refer to the step number(s) on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 4. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Code Setting Criteria (Fault) For Device Power Moding Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11393 Body Control Module: Reading and Clearing Diagnostic Trouble Codes With Diagnostic Scan Tool PROCEDURE A Tech II or equivalent Scan tool must be used to retrieve Diagnostic Trouble Codes (DTCs) from the PCM or BCM memory. DTCs can no longer be retrieved at the data link connector. This also eliminates the PCM function of flashing Code 12. Follow the instructions supplied by the Scan tool manufacturer in order to access and read either current and/or history DTCs. Without Diagnostic Scan Tool A Tech II or equivalent scan tool must be used to retrieve Diagnostic Trouble Codes (DTCs) from the PCM memory. DTCs can no longer be retrieved at the data link connector. This also eliminates the PCM function of flashing Code 12. Follow the instructions supplied by the scan tool manufacturer in order to access and read either current and/or history DTCs. With Diagnostic Scan Tool PROCEDURE Use a Tech II or equivalent Scan tool to clear Diagnostic Trouble Codes (DTCs) from the PCM memory. When clearing DTCs, follow the instructions supplied by the Scan tool manufacturer. NOTES: ^ Do not clear the DTCs unless directed to do so by the service information provided for each diagnostic procedure. All of the diagnostic data that was saved along with the DTC (freeze frame data and/or malfunction history records) which may be helpful for some diagnostic procedures will be erased from the memory when the DTCs are cleared. ^ Interrupting PCM battery voltage to clear DTCs is NOT recommended. Without Diagnostic Scan Tool PROCEDURE Use a Tech II or equivalent Scan tool to clear Diagnostic Trouble Codes (DTCs) from the PCM memory. When clearing DTCs, follow the instructions supplied by the Scan tool manufacturer. NOTES: ^ Do not clear the DTCs unless directed to do so by the service information provided for each diagnostic procedure. All of the diagnostic data that was saved along with the DTC (freeze frame data and/or malfunction history records) which may be helpful for some diagnostic procedures will be erased from the memory when the DTCs are cleared. ^ Interrupting PCM battery voltage to clear DTCs is NOT recommended. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11394 Body Control Module: Scan Tool Testing and Procedures Scan Tool Data Definitions Doors Battery Fd: The scan tool displays Inactive/Active. The input of the Doors Battery Fd is displayed as Active. Electronics Battery Fd: The scan tool displays Inactive/Active. The input of the Electronics Battery Fd is displayed as Active. Electronics System Gnd: The scan tool displays Inactive/Active. The input of the Electronics System Gnd is displayed as Active. Ignition 0: The scan tool displays On/Off. The input of the Ignition 0 varies on the scan tool display. Ignition 1: The scan tool displays On/Off. The input of the Ignition 1 varies on the scan tool display. Ignition 3: The scan tool displays On/Off. The input of the Ignition 3 varies on the scan tool display. Inadvert Power Relay: The scan tool displays On/Off. The input of the Inadvert Power Output varies on the scan tool display Loads Battery Fd: The scan tool displays Inactive/Active. The input of the Loads Battery Fd is displayed as Active. Loads System Gnd: The scan tool displays Inactive/Active. The input of the Loads System Gnd is displayed as Active. Theater Dim 1 Ground: The scan tool displays Inactive/Active. The input of the Theater Dim 1 Ground is displayed as Inactive. Theater Dim 2 Ground: The scan tool displays Inactive/Active. The input of the Theater Dim 2 Ground is displayed as Inactive. Scan Tool Data List Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures Body Control Module (BCM) Programming/RPO Configuration INTRODUCTION During body control module (BCM) related service, the procedures below are designated to set-up the BCM correctly. Before you start, read these procedures carefully and completely. SETUP NEW BODY CONTROL MODULE (BCM) IMPORTANT: ^ The BCM will not function properly if the Setup New BCM procedure is not performed. ^ Make sure the battery is fully charged before performing the setup procedure. ^ Make sure all disconnected devices and connectors have been reconnected ^ Perform the Theft Deterrent Re-learn procedure after successfully finishing the Setup New BCM procedure. Refer to Programming Theft Deterrent System Components in Theft Deterrent. If the Theft Deterrent Re-learn procedure is not performed after a BCM replacement, the following conditions may occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank nor start. 1. Connect a scan tool to the data link connector (DLC). 2. Turn the ignition switch ON. 3. Select Diagnostics and input all of the required data when prompted by the scan tool. 4. Select BODY CONTROL MODULE. 5. Select SPECIAL FUNCTIONS. 6. Select Setup New BCM. 7. Note, Input all of the required data when prompted by the scan tool. 8. Select Setup SDM Part Number in BCM, and follow the onscreen directions. 9. Select New VIN, and follow the onscreen directions. 10. Select Option Configuration, and follow the onscreen directions. 11. Select Point of Sale, and follow the onscreen directions. 12. Exit back to the SPECIAL FUNCTIONS menu. 13. When the BCM, VIN, Point of Sale and Option Configuration have been entered, proceed with Theft Deterrent Re-learn procedure. 14. If the scan tool displays UNABLE TO PROGRAM BCM, BCM IS SECURED, then the BCM must be replaced and this procedure must be repeated on a new BCM.. NOTE: After the above procedure has been completed, personalization of the BCM defaults to a default setting. Inform the customer that the personalization settings must be set again. IMPORTANT: After programing, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve History DTCs from all modules. 5. Clear all history DTCs General Information During Body Control Module (BCM) related service, the procedures below are designated to set-up the BCM correctly. Before you start, read these procedures carefully and completely. Theft Deterrent Re-Learn Using T-50 or T-60 1. Enter the T-50 or T-60 Service Programming System (SPS). 2. Select TERMINAL TO VEHICLE PROGRAMMING. 3. Select DONE. 4. Follow the instructions on the VEHICLE SETUP screen. 5. Select THEFT MODULE RE-LEARN. 6. Follow the instructions on the remaining screens. 7. The PCM and BCM will be prepared for re-learn. 8. A security timer will be on for approximately 10 minutes. During the 10 minute wait period, the T-50 or T-60 terminal must remain connected to the vehicle. 9. When the PCM and BCM are prepared to re-learn, turn the ignition switch off. 10. Turn the ignition switch to start. The vehicle should now start. Theft Deterrent Re-Learn W/O Scan Tool Or Techline Equipment This procedure takes approximately 30 minutes. Make sure the battery is fully charged before proceeding. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 11397 1. Turn the ignition switch off. 2. Turn the ignition switch all the way from the off to the start position, then leave it in the on position. NOTE: The engine will not crank. 3. The SECURITY will come on and stay on for at least 10 minutes. 4. Turn the ignition switch off for five seconds. 5. Repeat steps 2, 3, and 4 again for a second time. 6. Repeat steps 2, 3, and 4 again for a third time. 7. Turn the ignition switch off. 8. Turn the ignition switch all the way to the start position. The engine should now start. 9. Check for BCM Diagnostic Trouble Codes (DTCs). Theft Deterrent Re-Learn With Techline Equip & Tech 2 Scan Tool 1. Connect the Scan Tool to the Data Link Connector (DLC) on the vehicle. 2. At the Scan Tool main menu, select SERVICE PROGRAMMING. 3. Enter the requested information. 4. Select REQUEST INFO. 5. Disconnect the Scan Tool from the vehicle. 6. Connect the Scan Tool to the Techline terminal. 7. Select SERVICE PROGRAMMING SYSTEM (SPS). 8. Select TERMINAL TO TECH 2 PROGRAMMING. 9. Select DONE. 10. Follow instructions on the Techline terminal to Handheld Communications Setup screen. 11. Select THEFT MODULE RE-LEARN. 12. Select PROGRAM at the summary screen. The terminal will download information to the Scan Tool. 13. Disconnect the Scan Tool from the Techline terminal. 14. Connect the Scan Tool to the DLC on the vehicle. 15. At the Scan Tool main menu, select SERVICE PROGRAMMING. 16. Answer the question prompted by the Scan Tool. 17. Select RE-LEARN. 18. The Powertrain Control Module (PCM) and the BCM will be prepared for re-learn. 19. A security timer will be on for approximately 10 minutes. During the 10 minute wait period, Scan Tool must remain connected to the vehicle. 20. Turn the ignition switch off when the re-learn procedure is complete. 21. Turn the ignition switch to the start position. 22. The engine should start when the ignition switch is turned to the start position. 23. Disconnect the Scan Tool from the DLC. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 11398 Body Control Module: Removal and Replacement Body Control Module Replacement REMOVAL PROCEDURE IMPORTANT: You must perform the new body control module (BCM) setup when replacing the BCM. Refer to BCM Programming/RPO Configuration. 1. Disconnect the battery ground (negative) cable. 2. Remove the left instrument panel insulator. 3. Disconnect the BCM electrical connectors (2, 3, 4). 4. Remove the BCM (1). INSTALLATION PROCEDURE 1. Install the body control module (BCM) (1). 2. Connect the BCM electrical connectors (2, 3, 4). 3. Install the left instrument panel insulator 4. Connect the battery ground (negative) cable. 5. Perform the new BCM setup. Refer to BCM Programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting Front Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement Front Bumper Cover / Fascia: Service and Repair Fascia Grille Replacement Fascia Grille Replacement Tool Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Open the hood. 2. Remove the upper radiator air baffle. Refer to Radiator Air Baffle Assemblies and Deflectors (Upper) Radiator Air Baffle Assemblies and Deflectors (Side) Radiator Air Baffle Assemblies and Deflectors (Lower) in Engine Cooling. 3. Using J 38778 remove the push-in retainers from the upper grille. 4. Remove the circle retainers from the ends of the grille. 5. Remove the grille from the front bumper fascia, by pulling forward and up to release the retainers. Installation Procedure 1. Align the grille lower retainer tabs to the front bumper fascia. 2. Install the lower grille to the front bumper fascia, by pressing down until the tabs are fully seated. 3. Align the grille outer location pins by manipulate the front bumper fascia and pressing in the grille until fully seated. 4. Install the circle retainers to the ends of the grille. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 11407 5. Install the push-in retainers to the upper grille. 6. Install the upper radiator air baffle. Refer to Radiator Air Baffle Assemblies and Deflectors (Upper) Radiator Air Baffle Assemblies and Deflectors (Side) Radiator Air Baffle Assemblies and Deflectors (Lower) in Engine Cooling. 7. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 11408 Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Replacement Front Bumper Fascia Replacement (Impala) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Remove the front fender liners. Refer to Front Fender Liner Replacement (See: Fender/Front Fender/Front Fender Liner/Service and Repair) in Body Front End. 2. Remove the headlamps. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement (Impala) Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement (Monte Carlo) in Lighting Systems. 3. Remove the fog lamps, if equipped. Refer to Front Fog Lamp Replacement (Impala) Front Fog Lamp Replacement (Monte Carlo) in Lighting Systems. 4. Remove the nuts from the front bumper fascia at the fender. 5. Remove the push-in retainers from the upper front bumper fascia support using J 38778 . 6. Remove the screws from the front bumper fascia at the lower support. 7. Remove the front bumper fascia from the vehicle. 8. Remove the grille from the front bumper fascia. Refer to Fascia Grille Replacement (See: Fascia Grille Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 11409 9. Remove the front bumper fascia outer support. Refer to Front Bumper Fascia Outer Reinforcement Replacement (Impala) (See: Front Bumper Fascia Outer Reinforcement Replacement). Installation Procedure 1. Install the front bumper fascia outer support. Refer to Front Bumper Fascia Outer Reinforcement Replacement (Impala) (See: Front Bumper Fascia Outer Reinforcement Replacement). 2. Install the grille. Refer to Fascia Grille Replacement (See: Fascia Grille Replacement). 3. Install the fascia to the vehicle. 4. Install the push-in retainers to the front upper bumper fascia support. Notice: Refer to Fastener Notice in Cautions and Notices. 5. Install the front bumper fascia to lower support bolts. Tighten the front bumper fascia lower support screws to 2 Nm (18 lb in). 6. Install the front bumper fascia to fender nuts. Tighten the front bumper fascia nuts to 6 Nm (53 lb in). 7. Install the front fender liners. Refer to Front Fender Liner Replacement (See: Fender/Front Fender/Front Fender Liner/Service and Repair) in Body Front End. 8. Install the fog lamps, if equipped. Refer to Front Fog Lamp Replacement (Impala) Front Fog Lamp Replacement (Monte Carlo) in Lighting Systems. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 11410 9. Install the headlamps. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement (Impala) Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement (Monte Carlo) in Lighting Systems. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 11411 Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Extension Replacement Front Bumper Fascia Extension Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Drill out the plastic rivets from the front bumper fascia extension corner to the front fender liner. 3. Remove the lower fascia support. Refer to Front Bumper Fascia Lower Support Replacement (Impala) (See: Front Bumper Fascia Lower Support Replacement)Front Bumper Fascia Lower Support Replacement (Monte Carlo) (See: Front Bumper Fascia Lower Support Replacement) in Bumpers. 4. Remove the front fender liner to front bumper fascia screws. 5. Remove the spring clips from the fascia extension. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 11412 6. Remove the fascia extension. Installation Procedure 1. Position the fascia extension to the fascia. 2. Install the spring clips starting at the center of the fascia extension and working outward. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws to the front fender liner at the front of the front bumper fascia. Tighten the front fender liner to fascia screws to 2 Nm (18 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 11413 4. Using new plastic rivets, install the 2 plastic rivets to the front bumper fascia extension corner and front fender liner. 5. Install the lower fascia support. Refer to Front Bumper Fascia Lower Support Replacement (Impala) (See: Front Bumper Fascia Lower Support Replacement)Front Bumper Fascia Lower Support Replacement (Monte Carlo) (See: Front Bumper Fascia Lower Support Replacement) in Bumpers. 6. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 11414 Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Outer Reinforcement Replacement Front Bumper Fascia Outer Reinforcement Replacement (Impala) Removal Procedure 1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement (Impala) (See: Front Bumper Fascia Replacement). 2. Drill out the 2 rivets from the front bumper fascia reinforcement outer. 3. Remove the front bumper fascia reinforcement outer. Installation Procedure 1. Align the front bumper fascia reinforcement outer to the front bumper fascia. 2. Install the front bumper fascia reinforcement outer to the front bumper fascia using two new rivets. 3. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement (Impala) (See: Front Bumper Fascia Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 11415 Front Bumper Cover / Fascia: Service and Repair Fascia Grille Replacement Fascia Grille Replacement Tool Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Open the hood. 2. Remove the upper radiator air baffle. Refer to Radiator Air Baffle Assemblies and Deflectors (Upper) Radiator Air Baffle Assemblies and Deflectors (Side) Radiator Air Baffle Assemblies and Deflectors (Lower) in Engine Cooling. 3. Using J 38778 remove the push-in retainers from the upper grille. 4. Remove the circle retainers from the ends of the grille. 5. Remove the grille from the front bumper fascia, by pulling forward and up to release the retainers. Installation Procedure 1. Align the grille lower retainer tabs to the front bumper fascia. 2. Install the lower grille to the front bumper fascia, by pressing down until the tabs are fully seated. 3. Align the grille outer location pins by manipulate the front bumper fascia and pressing in the grille until fully seated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 11416 4. Install the circle retainers to the ends of the grille. 5. Install the push-in retainers to the upper grille. 6. Install the upper radiator air baffle. Refer to Radiator Air Baffle Assemblies and Deflectors (Upper) Radiator Air Baffle Assemblies and Deflectors (Side) Radiator Air Baffle Assemblies and Deflectors (Lower) in Engine Cooling. 7. Close the hood. Front Bumper Fascia Replacement Front Bumper Fascia Replacement (Impala) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Remove the front fender liners. Refer to Front Fender Liner Replacement (See: Fender/Front Fender/Front Fender Liner/Service and Repair) in Body Front End. 2. Remove the headlamps. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement (Impala) Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement (Monte Carlo) in Lighting Systems. 3. Remove the fog lamps, if equipped. Refer to Front Fog Lamp Replacement (Impala) Front Fog Lamp Replacement (Monte Carlo) in Lighting Systems. 4. Remove the nuts from the front bumper fascia at the fender. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 11417 5. Remove the push-in retainers from the upper front bumper fascia support using J 38778 . 6. Remove the screws from the front bumper fascia at the lower support. 7. Remove the front bumper fascia from the vehicle. 8. Remove the grille from the front bumper fascia. Refer to Fascia Grille Replacement (See: Fascia Grille Replacement). 9. Remove the front bumper fascia outer support. Refer to Front Bumper Fascia Outer Reinforcement Replacement (Impala) (See: Front Bumper Fascia Outer Reinforcement Replacement). Installation Procedure 1. Install the front bumper fascia outer support. Refer to Front Bumper Fascia Outer Reinforcement Replacement (Impala) (See: Front Bumper Fascia Outer Reinforcement Replacement). 2. Install the grille. Refer to Fascia Grille Replacement (See: Fascia Grille Replacement). 3. Install the fascia to the vehicle. 4. Install the push-in retainers to the front upper bumper fascia support. Notice: Refer to Fastener Notice in Cautions and Notices. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 11418 5. Install the front bumper fascia to lower support bolts. Tighten the front bumper fascia lower support screws to 2 Nm (18 lb in). 6. Install the front bumper fascia to fender nuts. Tighten the front bumper fascia nuts to 6 Nm (53 lb in). 7. Install the front fender liners. Refer to Front Fender Liner Replacement (See: Fender/Front Fender/Front Fender Liner/Service and Repair) in Body Front End. 8. Install the fog lamps, if equipped. Refer to Front Fog Lamp Replacement (Impala) Front Fog Lamp Replacement (Monte Carlo) in Lighting Systems. 9. Install the headlamps. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement (Impala) Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement (Monte Carlo) in Lighting Systems. Front Bumper Fascia Extension Replacement Front Bumper Fascia Extension Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Drill out the plastic rivets from the front bumper fascia extension corner to the front fender liner. 3. Remove the lower fascia support. Refer to Front Bumper Fascia Lower Support Replacement (Impala) (See: Front Bumper Fascia Lower Support Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 11419 Replacement)Front Bumper Fascia Lower Support Replacement (Monte Carlo) (See: Front Bumper Fascia Lower Support Replacement) in Bumpers. 4. Remove the front fender liner to front bumper fascia screws. 5. Remove the spring clips from the fascia extension. 6. Remove the fascia extension. Installation Procedure 1. Position the fascia extension to the fascia. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 11420 2. Install the spring clips starting at the center of the fascia extension and working outward. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws to the front fender liner at the front of the front bumper fascia. Tighten the front fender liner to fascia screws to 2 Nm (18 lb in). 4. Using new plastic rivets, install the 2 plastic rivets to the front bumper fascia extension corner and front fender liner. 5. Install the lower fascia support. Refer to Front Bumper Fascia Lower Support Replacement (Impala) (See: Front Bumper Fascia Lower Support Replacement)Front Bumper Fascia Lower Support Replacement (Monte Carlo) (See: Front Bumper Fascia Lower Support Replacement) in Bumpers. 6. Lower the vehicle. Front Bumper Fascia Outer Reinforcement Replacement Front Bumper Fascia Outer Reinforcement Replacement (Impala) Removal Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 11421 1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement (Impala) (See: Front Bumper Fascia Replacement). 2. Drill out the 2 rivets from the front bumper fascia reinforcement outer. 3. Remove the front bumper fascia reinforcement outer. Installation Procedure 1. Align the front bumper fascia reinforcement outer to the front bumper fascia. 2. Install the front bumper fascia reinforcement outer to the front bumper fascia using two new rivets. 3. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement (Impala) (See: Front Bumper Fascia Replacement). Front Bumper Fascia Upper Support Replacement Front Bumper Fascia Upper Support Replacement (Impala) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the hood. 2. Remove the headlamps. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement (Impala) Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement (Monte Carlo) in Lighting Systems. 3. Remove the push-in retainers from the front bumper fascia upper support using J 38778 . Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 11422 4. Remove the front bumper fascia upper support bolts. 5. Remove the front bolt from the front bumper fascia upper support to the hood latch support bracket. 6. Remove the front bumper fascia upper support from the front bumper fascia. Installation Procedure 1. Install the front bumper fascia upper support to the front bumper fascia. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the front bumper fascia upper support bolts. Tighten the front bumper fascia upper support bolts to 10 Nm (89 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 11423 3. Install the front bumper fascia upper support to hood latch support bracket bolt. Tighten the hood latch support bracket bolts to 10 Nm (89 lb in). 4. Install the center support bracket bolt. Tighten the center support bracket bolt to 10 Nm (89 lb in). 5. Install the push-in retainers to the front bumper fascia upper support. 6. Install the headlamps. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement (Impala) Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement (Monte Carlo) in Lighting Systems. 7. Check the headlamp aim; if a new headlamp was installed, or if service or repairs in the front end area may have disturbed the headlamp mounting brackets. Refer to Headlamp Aiming (Impala) Headlamp Aiming (Monte Carlo) . 8. Close the hood. Front Bumper Fascia Lower Support Replacement Front Bumper Fascia Lower Support Replacement (Impala) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 11424 1. Remove the screws from the lower front bumper fascia. 2. Remove the push-in retainers from the front bumper fascia lower support at the front bumper impact bar using J 38778 . 3. Remove the front bumper fascia lower support from the front bumper fascia and front bumper impact bar. Installation Procedure 1. Install the front bumper fascia lower support to the front bumper impact bar. 2. Install the push-in the retainers to the front bumper fascia lower support at the front of the bumper impact bar. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws to the lower front bumper fascia. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 11425 Tighten the screws to the lower front bumper fascia to 2 Nm (18 lb in). Front Upper Fascia Support Bracket Replacement Front Upper Fascia Support Bracket Replacement Removal Procedure 1. Open the hood. 2. Remove the upper radiator air baffle. Refer to Radiator Air Baffle Assemblies and Deflectors (Upper) Radiator Air Baffle Assemblies and Deflectors (Side) Radiator Air Baffle Assemblies and Deflectors (Lower) in Engine Cooling. 3. Remove the bolts from the front bumper fascia center support bracket. 4. Remove the front bumper fascia center support bracket from the hood latch center support. Installation Procedure 1. Align the front bumper fascia center support bracket to the hood latch center support and the front bumper fascia upper support. 2. Install the bolts to the hood latch center support and hand tighten. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the bolt to the front bumper fascia upper support. Tighten the bolt to the front bumper fascia upper support to 10 Nm (89 lb in). 4. Tighten the bolts to the hood latch center support. Tighten the bolts to the hood latch center support to 10 Nm (89 lb in). 5. Install the upper radiator air baffle. Refer to Radiator Air Baffle Assemblies and Deflectors (Upper) Radiator Air Baffle Assemblies and Deflectors (Side) Radiator Air Baffle Assemblies and Deflectors (Lower) in Engine Cooling. 6. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Polypropylene Energy Absorber Replacement Front Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Page 11430 Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Replacement (Impala) Removal Procedure 1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement (Impala) (See: Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 2. Remove the front bumper energy absorber. Refer to Front Bumper Fascia Energy Absorber Replacement (Impala) (See: Front Bumper Shock Absorber/Service and Repair). 3. Remove the wiring harness from the rear of front bumper impact bar. 4. Remove the front bumper impact bar bolts. 5. Remove the front bumper impact bar. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Page 11431 1. Install the front bumper impact bar to the body. Notice: Refer to Fastener Notice in Cautions and Notices. Important: The upper right hand location is a net hole locator and must be installed first. 2. Install the front bumper impact bar bolts. Tighten the front bumper impact bar bolts to 25 Nm (18 lb ft). 3. Install the wiring harness to the rear of the front bumper impact bar. 4. Install the front bumper energy absorber. Refer to Front Bumper Fascia Energy Absorber Replacement (Impala) (See: Front Bumper Shock Absorber/Service and Repair). 5. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement (Impala) (See: Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Shock Absorber > System Information > Service and Repair Front Bumper Shock Absorber: Service and Repair Front Bumper Fascia Energy Absorber Replacement (Impala) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement (Impala) (See: Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 2. Use J 38778 to remove the push-in retainers from the front bumper energy absorber. 3. Remove the front bumper energy absorber from the front bumper impact bar. Installation Procedure 1. Install the front bumper energy absorber to the front bumper impact bar. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Shock Absorber > System Information > Service and Repair > Page 11435 2. Install the push-in retainers to the front bumper energy absorber. 3. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement (Impala) (See: Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting Rear Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia Extension Replacement Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia Extension Replacement Rear Bumper Fascia Extension Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the rear tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 3. Drill out the plastic rivet from the rear fascia extension corner to the splash shield. 4. Remove the rear bumper fascia extension screw from the rear fascia extension corner to the splash shield. 5. Remove the rear bumper fascia extension lower screw from the lower rear fascia to splash shield. 6. Drill out the rivets from the lower rear end of the rear fascia extension. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia Extension Replacement > Page 11443 7. Remove the spring clips from the fascia extension. 8. Remove the fascia extension. Installation Procedure 1. Install the fascia extension onto the fascia. 2. Install the spring clips through the tabs in the fascia extension. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia Extension Replacement > Page 11444 3. Using new plastic rivets, install the plastic rivets to the lower rear end of the rear fascia extension. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the rear bumper fascia extension lower screw to the lower rear fascia and splash shield. Tighten the rear bumper fascia extension lower screw to 2 Nm (18 lb in). 5. Using a new plastic rivet, install the plastic rivet to the rear fascia extension corner to the splash shield. 6. Install the rear bumper fascia extension screw to the rear fascia extension corner to the splash shield. Tighten the rear bumper fascia extension screw to 2 Nm (18 lb in). 7. Install the rear wheels and tires. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia Extension Replacement > Page 11445 Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia Replacement Rear Bumper Fascia Replacement (Impala) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Remove the license plate lamp. Refer to Rear License Plate Lamp Replacement (Impala) Rear License Plate Lamp Replacement (Monte Carlo) in Lighting Systems. 2. Pull back the rear compartment trim panel. Refer to Rear Compartment Trim Panel Replacement (Two Section) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Compartment Trim Panel Replacement (Two Section)) in Body Rear End. 3. Remove the nuts from the rear bumper fascia outer retainers. 4. Remove the bolts in the rear compartment from the rear bumper fascia outer retainers. 5. Remove the rear bumper fascia splash shield. Refer to Rear Bumper Fascia Splash Shield Replacement (See: Rear Bumper Fascia Splash Shield Replacement). 6. Remove the bolts from the rear bumper fascia outer retainers. 7. Remove the push-in retainers from the rear bumper fascia at the rear impact bar, using the J 38778 . 8. Remove the rear bumper fascia from the vehicle. Installation Procedure 1. Position the rear bumper fascia to the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia Extension Replacement > Page 11446 2. Install the push-in retainers to the rear bumper fascia. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the nuts to the rear bumper fascia outer retainers. Tighten the rear bumper fascia outer retainer nuts to 6 Nm (53 lb in). 4. Install the bolts to the rear bumper fascia outer retainers. Tighten the rear bumper fascia outer retainer bolts to 6 Nm (53 lb in). 5. Install the nut to the rear bumper fascia outer retainer. Tighten the rear bumper fascia outer retainer nut to 6 Nm (53 lb in). 6. Install the rear bumper fascia splash shield. Refer to Rear Bumper Fascia Splash Shield Replacement (See: Rear Bumper Fascia Splash Shield Replacement). 7. Pull back the rear compartment trim panel. Refer to Rear Compartment Trim Panel Replacement (Two Section) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Compartment Trim Panel Replacement (Two Section)) in Body Rear End. 8. Install the license plate lamp. Refer to Rear License Plate Lamp Replacement (Impala) Rear License Plate Lamp Replacement (Monte Carlo) in Lightning Systems. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia Extension Replacement > Page 11447 Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia Splash Shield Replacement Rear Bumper Fascia Splash Shield Replacement Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Drill out the plastic rivet from the rear fascia extension corner if equipped. 2. Remove the rear bumper fascia extension screw if equipped. 3. Remove the rear bumper fascia splash shield nuts. 4. Remove the rear bumper fascia splash shield bolt. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia Extension Replacement > Page 11448 5. Remove the rear bumper fascia push-in retainer using J 38778 . 6. Remove the rear bumper fascia splash shield screws. 7. Remove the rear bumper fascia splash shield. Installation Procedure 1. Install the rear bumper fascia splash shield over the studs. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the rear bumper fascia splash shield nuts. Tighten the rear bumper fascia splash shield nuts to 2 Nm (18 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia Extension Replacement > Page 11449 3. Install the rear bumper fascia splash shield bolt. Tighten the rear bumper fascia splash shield bolts to 2 Nm (18 lb in). 4. Install the rear bumper fascia splash shield screws. Tighten the rear bumper fascia splash shield nut to 2 Nm (18 lb in). 5. Install the rear bumper fascia splash shield push-in retainers. 6. Using a new plastic rivet,install the plastic rivet to the rear fascia extension corner to splash shield if equipped. 7. Install the rear bumper fascia extension screw to the rear fascia extension corner to splash shield if equipped. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia Extension Replacement > Page 11450 Tighten the rear bumper fascia extension screw to 2 Nm (18 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia Extension Replacement > Page 11451 Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia Outer Support Replacement Rear Bumper Fascia Outer Support Replacement (Impala) Tools Required J 38778 Door Trim Pad Clip Removal Removal Procedure 1. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement (Impala) (See: ). 2. Remove the rear bumper fascia reinforcement outer push-in retainers using J 38778 . 3. Remove the rear bumper fascia reinforcement outer from the rear bumper fascia. Installation Procedure 1. Install the rear bumper fascia reinforcement outer to the rear bumper fascia. 2. Install the rear bumper fascia reinforcement outer push-in retainers. 3. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement (Impala) (See: . Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Polypropylene Energy Absorber Replacement Rear Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Technical Service Bulletins > Page 11456 Rear Bumper Reinforcement: Service and Repair Rear Bumper Impact Bar Replacement (Impala) Removal Procedure 1. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement (Impala) (See: Rear Bumper Cover / Fascia/Service and Repair). 2. Remove the rear bumper energy absorber. Refer to Rear Energy Absorber Replacement (Impala) (See: Rear Bumper Shock Absorber/Service and Repair. 3. Remove the rear bumper impact bar bolts. 4. Remove the rear bumper impact bar. Installation Procedure 1. Install the rear bumper impact bar to the body. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Technical Service Bulletins > Page 11457 Notice: Refer to Fastener Notice in Cautions and Notices. Important: The lower outboard location is a 4-way net hole locator and must be installed first. 2. Install the rear bumper impact bar bolts. Tighten the rear bumper impact bar bolts to 25 Nm (18 lb ft). 3. Install the rear bumper energy absorber. Refer to Rear Energy Absorber Replacement (Impala) (See: Rear Bumper Shock Absorber/Service and Repair. 4. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement (Impala) (See: Rear Bumper Cover / Fascia/Service and Repair). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Shock Absorber > System Information > Service and Repair Rear Bumper Shock Absorber: Service and Repair Rear Energy Absorber Replacement (Impala) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement (Impala) (See: Rear Bumper Cover / Fascia/Service and Repair). 2. Remove the push-in retainers from the rear bumper energy absorber using J 38778 . 3. Remove the rear bumper energy absorber from the rear bumper impact bar. Installation Procedure 1. Position the rear bumper energy absorber to the rear bumper impact bar. 2. Install the push-in retainers to the rear bumper energy absorber. 3. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement (Impala) (See: Rear Bumper Cover / Fascia/Service and Repair). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Open the rear compartment. 2. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement (Impala) (See: Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair)Rear Bumper Fascia Replacement (Monte Carlo) (See: Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair) in Bumpers. 3. Pull back the rear compartment trim panel. 4. Apply pressure at 2 upper locations and 2 lower locations, using a small, flat-bladed tool in order to release the retainers on the pressure relief valve. 5. Remove the pressure relief valve from the lower quarter panel. Installation Procedure 1. Install the pressure relief valve to the lower quarter panel. 2. Press the pressure relief valve into the quarter lower panel until the retainers lock into place at the upper and lower locations. 3. Pull back the rear compartment trim panel. 4. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement (Impala) (See: Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair)Rear Bumper Fascia Replacement (Monte Carlo) (See: Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair) in Bumpers. 5. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Plenum Water Deflector Replacement Cowl Moulding / Trim: Service and Repair Plenum Water Deflector Replacement Plenum Water Deflector Replacement Removal Procedure 1. Open the hood. 2. Remove the right side of the air inlet grille. Refer to Air Inlet Grille Panel Replacement (See: Air Inlet Grille Panel Replacement). 3. Remove the plenum chamber deflector from the pinch-weld flange, by lifting up and out. Installation Procedure 1. Install the plenum chamber deflector to the pinch-weld flange. 2. Install the right side of the air inlet grille. Refer to Air Inlet Grille Panel Replacement (See: Air Inlet Grille Panel Replacement). 3. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Plenum Water Deflector Replacement > Page 11469 Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Air Inlet Grille Panel Replacement Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the hood. 2. Remove the wiper arms. Refer to Windshield Wiper Arm Replacement in Wipers/Washer Systems. 3. Disconnect the windshield wiper washer hose from the air inlet grille. 4. Use the J 38778 to remove the push-in retainers from the air inlet grille. 5. Remove the air inlet grille from the vehicle. Installation Procedure 1. Install the air inlet grille to the vehicle. 2. Install the push-in retainers to the air inlet grille. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Plenum Water Deflector Replacement > Page 11470 3. Install the windshield wiper washer hose to the air inlet grille. 4. Install the wiper arms. Refer to Windshield Wiper Arm Replacement in Wipers/Washer Systems. 5. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair Front Side Door Outside Handle Replacement (Impala) Removal Procedure Important: The outside handles have adjustable lock rod. This allows for adjustment of the amount of travel needed to operate the outside handle. When servicing a vehicle with adjustable outside handle-to-lock rods, it is important that all free play between the outside handle and the lock be removed. Do not operate the outside handle before these adjustments are made. Before removing the door handle, apply a double layer of masking tape around the perimeter of the painted surfaces. 1. Position the window completely up. 2. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement. See: Front Door Panel/Service and Repair 3. Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement. See: Front Door Panel/Service and Repair 4. Remove the front door rear window channel bolt. 5. Remove the front door rear window channel from the front door slot by pulling downward to disengage the retainer clip. 6. Remove the outside door handle rod-to-lock clip from the lock. 7. Remove the front door outside handle lock cylinder. Refer to Door Lock Cylinder Replacement (Impala) (See: Locks/Door Locks/Door Lock Cylinder/Service and Repair). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 11478 8. Remove the hole plug to access to one of the two bolts that attach the outer door handle. 9. Remove the front door outside door handle from the door. 10. Remove the front door outside door handle rod from the handle. Installation Procedure 1. Install the lock cylinder retainer clip to door handle. 2. Install the front door handle rod to the door handle. 3. Install the front outside door handle to the door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 11479 Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the front door outside door handle bolts. Tighten the front door outside door handle bolts to 10 Nm (89 lb in). 5. Install the front door outside handle lock cylinder. Refer to Door Lock Cylinder Replacement (Impala) (See: Locks/Door Locks/Door Lock Cylinder/Service and Repair). 6. Install a NEW outside handle rod-to-lock clip onto the door lock lever. * Position the outside door handle rod in the clip to eliminate any free play in the outside door handle. * Install the clip cover over the threaded outside door handle rod. 7. Install the front door rear window channel to the front door, ensuring that the up clip is engaged to the upper channel. 8. Install the front door rear window channel bolt. Notice: Refer to Fastener Notice in Cautions and Notices. Install the front door rear window channel bolt. Tighten the front door rear window channel bolt to 10 Nm (89 lb in). 9. Install the access hole plug. 10. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement. See: Front Door Panel/Service and Repair 11. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement. See: Front Door Panel/Service and Repair Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Door Handle Replacement Front Door Interior Handle: Service and Repair Door Handle Replacement Front Side Door Inside Handle Rod Replacement (Impala) Removal Procedure 1. Remove the front door lock. Refer to Front Side Door Lock Replacement (Impala) (See: Locks/Door Locks/Service and Repair/Removal and Replacement/Front Side Door Lock Replacement). 2. Remove the front door inside handle rod from the front door lock. Installation Procedure 1. Install the front door inside handle rod to the front door lock. Push in and rotate the rod through the clip in order to secure the rod. 2. Install the front door lock. Refer to Front Side Door Lock Replacement (Impala) (See: Locks/Door Locks/Service and Repair/Removal and Replacement/Front Side Door Lock Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Door Handle Replacement > Page 11484 Front Door Interior Handle: Service and Repair Door Handle Components Front Side Door Inside Handle Rod Replacement (Impala) Removal Procedure 1. Remove the front door lock. Refer to Front Side Door Lock Replacement (Impala) (See: Locks/Door Locks/Service and Repair/Removal and Replacement/Front Side Door Lock Replacement). 2. Remove the front door inside handle rod from the front door lock. Installation Procedure 1. Install the front door inside handle rod to the front door lock. Push in and rotate the rod through the clip in order to secure the rod. 2. Install the front door lock. Refer to Front Side Door Lock Replacement (Impala) (See: Locks/Door Locks/Service and Repair/Removal and Replacement/Front Side Door Lock Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair Front Door Hinge: Service and Repair Door Hinge Replacement (Impala Front) Removal Procedure Important: In order to minimize door realignment, do not remove both door hinges at the same time. Do each door hinge separately, and replace the broken door hinge first. 1. Open the front door. 2. Clean the mounting surfaces of the hinges with a clean rag and mark the front door hinge locations on each surface with a grease pencil or other suitable marker. 3. Support the front door. 4. Remove the bolts from the bodyside front door hinge. 5. Remove the bolts from the doorside front door hinge. 6. Remove the front door hinge from the vehicle. Installation Procedure 1. Position the front door hinge to the alignment marks. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts to the bodyside front door hinge. Tighten the bolts to the bodyside front door hinge to 33 Nm (24 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Page 11488 3. Install the bolts to the doorside front door hinge. Tighten the bolts to the doorside front door hinge to 33 Nm (24 lb ft). 4. Remove the door support. 5. Inspect the door for proper operation and alignment. Refer to Door Adjustment (Rear) (See: Rear Door/Adjustments)Door Adjustment (Front) ( See: Adjustments). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door Inside Handle Bezel Replacement Front Door Panel: Service and Repair Door Inside Handle Bezel Replacement Door Inside Handle Bezel Replacement (Impala) Removal Procedure 1. Remove the inside door handle bezel screw. 2. Remove the inside door handle bezel from the front door trim panel. 3. Remove the front door lock switch from the inside door handle bezel. Refer to Door Lock Switch Replacement (Impala) (See: Locks/Power Locks/Power Door Lock Switch/Service and Repair/Removal and Replacement). 4. Remove the inside door handle bezel from the vehicle. Installation Procedure 1. Install the front door lock switch to the inside door handle bezel. Refer to Door Lock Switch Replacement (Impala) (See: Locks/Power Locks/Power Door Lock Switch/Service and Repair/Removal and Replacement). 2. Install the inside door handle bezel to the front door trim panel. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screw to the inside door handle bezel. Tighten the inside door handle bezel screw to 2 Nm (18 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door Inside Handle Bezel Replacement > Page 11493 Front Door Panel: Service and Repair Front Side Door Warning Reflector Replacement Front Side Door Warning Reflector Replacement Removal Procedure 1. Open the door. 2. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (Impala) Front Side Door Trim Panel Replacement (Monte Carlo). 3. Grind off the four plastic tabs which were melted to hold the reflector in place. 4. Remove the reflector. Installation Procedure 1. Install the warning reflector on the trim panel by pressing the tabs back into the trim panel. 2. Melt the tabs to secure the reflector to the trim panel. 3. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (Impala) Front Side Door Trim Panel Replacement (Monte Carlo). 4. Close the door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door Inside Handle Bezel Replacement > Page 11494 Front Door Panel: Service and Repair Front Side Door Water Deflector Replacement Front Side Door Water Deflector Replacement (Impala) Removal Procedure 1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (Impala). 2. Remove the front door pull handle bracket from the front door inner panel. 3. Disconnect all of the required electrical connectors. 4. Remove the inside door handle gasket from. 5. Remove the front door water deflector from the front door inner panel. Installation Procedure 1. Align the front door water deflector to the front door inner panel. Secure the water deflector at the corners. 2. Pull the front door wiring harness leads through the slits in the front door water deflector. 3. Install the front door water deflector, start pressing the adhesive pattern at the bottom center and working outward and upward in order to prevent puckering. 4. Install the inside door handle gasket. 5. Connect all of the required electrical connectors. 6. Install the front door pull handle bracket to the front door inner panel. 7. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (Impala). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door Inside Handle Bezel Replacement > Page 11495 Front Door Panel: Service and Repair Panel Replacement Front Side Door Trim Panel Replacement (Impala) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Remove the front door handle trim bezel. Refer to Door Inside Handle Bezel Replacement (Impala) (See: Door Inside Handle Bezel Replacement ). 2. Remove the front door pull cup. Refer to Armrest Pull Cup Replacement (Impala) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Removal and Replacement/Armrest Pull Cup Replacement). 3. Remove the door trim panel screws from the pull cup support bracket. 4. Disconnect and reposition the electrical connectors. 5. Remove the two screws from the door pull handle bracket. 6. Remove the front door trim panel using the J 38778 in order to disengage the fasteners from the door inner panel. 7. Remove the screw from the upper door trim panel. 8. Remove the upper door trim panel from the front door. Installation Procedure Important: Before installing the front door trim panel to the front door inner panel, the old trim panel retainers MUST be discarded and Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door Inside Handle Bezel Replacement > Page 11496 replaced with NEW trim panel retainers. 1. Install the upper door trim panel to the front door. 2. Install the screw to the upper door trim panel. 3. Install the front door trim panel to the inner door panel. 4. Install the two screws to the door pull handle bracket. 5. Connect and position the electrical connectors in place. 6. Install the front door pull cup. Refer to Armrest Pull Cup Replacement (Impala) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Removal and Replacement/Armrest Pull Cup Replacement). 7. Install the front door handle trim bezel. Refer to Door Inside Handle Bezel Replacement (Impala) (See: Door Inside Handle Bezel Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments > Door Lock Striker Adjustment (With Clay or Caulk) Front Door Striker: Adjustments Door Lock Striker Adjustment (With Clay or Caulk) Door Lock Striker Adjustment (With Clay or Caulk) Important: Properly align the door before adjusting the striker. 1. Open the door. 2. Loosen the door striker screws just enough to allow movement of the door striker. 3. Adjust the door striker up or down and inboard or outboard as required. 4. Apply modeling clay or body caulking compound to the door lock opening. Important: Do not close the door all the way. 5. Close the door far enough for the striker to make an impression into the modeling clay or body caulking compound. 6. Open the door and check the door striker impression in the modeling clay or body caulking compound. Notice: Refer to Fastener Notice in Cautions and Notices. 7. Readjust door striker as required. Add or remove spacers as needed. Tighten the door striker screws to 25 Nm (18 lb ft). 8. Close the door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments > Door Lock Striker Adjustment (With Clay or Caulk) > Page 11501 Front Door Striker: Adjustments Door Lock Striker Adjustment (With Mini Wedge) Door Lock Striker Adjustment (With Mini Wedge) Tools Required J 39346-A Mini Wedge Door Striker Aligner Important: Properly align the door before adjusting the striker. 1. Open the door. 2. Loosen the door striker screws just enough to allow movement of the door striker. 3. Install the J 39346-A . Important: Do not slam the door. 4. Close the door while holding the outside handle in the open position. 5. Open the door. Notice: Refer to Fastener Notice in Cautions and Notices. 6. Tighten the door lock striker screws. Tighten the door striker screws to 25 Nm (18 lb ft). 7. Remove the J 39346-A . 8. Close the door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments > Page 11502 Front Door Striker: Service and Repair Door Striker Anchor Plate Replacement Removal Procedure 1. Remove the front or rear door lock pillar trim to gain access to the anchor plate. 1. Remove the center pillar upper trim panel. (Front Striker) Refer to Center Pillar Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Trim Panel Replacement). 2. Remove the center pillar lower trim panel. (Front Striker) Refer to Center Pillar Lower Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Lower Trim Panel Replacement). 3. Remove the quarter lower trim panel. (Rear Striker). Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Lower Rear Trim Panel Replacement)Quarter Lower Rear Trim Panel Replacement (Monte Carlo) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Lower Rear Trim Panel Replacement). 2. Mark the position of the striker with a grease pencil. 3. Remove the screws from the front door lock striker. 4. Remove the striker and the shims. 5. Remove the anchor plate. Installation Procedure 1. Install the anchor plate. 2. Install the door lock shims and striker. 3. Install the striker screws. 4. Align the door lock striker to the alignment marks. Notice: Refer to Fastener Notice in Cautions and Notices. 5. Tighten the door lock striker screws. Tighten the striker screws to 25 Nm (18 lb ft). 6. Adjust door lock striker if required. Refer to Door Lock Striker Adjustment (With Mini Wedge) (See: Adjustments/Door Lock Striker Adjustment (With Mini Wedge))Door Lock Striker Adjustment (With Clay or Caulk) (See: Adjustments/Door Lock Striker Adjustment (With Clay or Caulk)). 7. Install the front and/or rear trim. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments > Page 11503 1. Install the center pillar upper trim panel. (Front Striker) Refer to Center Pillar Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Trim Panel Replacement). 2. Install the center pillar lower trim panel. (Front Striker) Refer to Center Pillar Lower Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Lower Trim Panel Replacement). 3. Install the quarter lower trim panel. (Rear Striker). Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Lower Rear Trim Panel Replacement)Quarter Lower Rear Trim Panel Replacement (Monte Carlo) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Lower Rear Trim Panel Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Opening Weatherstrip Replacement Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement Front Door Opening Weatherstrip Replacement (Impala) Removal Procedure 1. Open the front door. 2. Remove the carpet retainers. Refer to Front Side Door Opening Floor Carpet Retainer Replacement (See: Interior Moulding / Trim/Carpet/Service and Repair/Front Side Door Opening Floor Carpet Retainer Replacement) in Interior Trim. 3. Remove the windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement) in Interior Trim. 4. Remove the upper center pillar trim panel. Refer to Center Pillar Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Trim Panel Replacement) in Interior Trim. 5. Remove the center lower trim panel. Refer to Center Pillar Lower Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Lower Trim Panel Replacement) in Interior Trim. 6. Remove the front door opening weatherstrip by pulling it off the pinch-weld flange. Installation Procedure 1. Position the front door opening weatherstrip to the pinch-weld flange. Starting at the center of the rocker panel area and moving in a clockwise direction press the front door opening weatherstrip to the pinch-weld flange until fully seated. Important: The joint butt ends must have no gap and be located in the center of the of the rocker panel area. 2. Install joint butt ends together. 3. Install the carpet retainers. Refer to Front Side Door Opening Floor Carpet Retainer Replacement (See: Interior Moulding / Trim/Carpet/Service and Repair/Front Side Door Opening Floor Carpet Retainer Replacement) in Interior Trim. 4. Install the windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement) in Interior Trim. 5. Install the upper center pillar trim panel. Refer to Center Pillar Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Trim Panel Replacement) in Interior Trim. 6. Install the center lower trim panel. Refer to Center Pillar Lower Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Lower Trim Panel Replacement) in Interior Trim. 7. Close the front door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Opening Weatherstrip Replacement > Page 11508 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Opening REMOVAL PROCEDURE 1. Open the front door. 2. Remove the carpet retainers. 3. Remove the windshield garnish molding. 4. Remove the upper center pillar trim panel. 5. Remove the center lower trim panel. 6. Remove the front door opening weatherstrip by pulling it off the pinch-weld flange. INSTALLATION PROCEDURE 1. Position the front door opening weatherstrip to the pinch-weld flange. Starting at the center of the rocker panel area and moving in a clockwise direction press the front door opening weatherstrip to the pinch-weld flange until fully seated. IMPORTANT: The joint butt ends must have no gap and be located in the center of the of the rocker panel area. 2. Install joint butt ends together. 3. Install the carpet retainers. 4. Install the windshield garnish molding. 5. Install the upper center pillar trim panel. 6. Install the center lower trim panel. 7. Close the front door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Opening Weatherstrip Replacement > Page 11509 Front Door Weatherstrip: Service and Repair Door Bottom Auxiliary Sealing Strip Replacement (Front) Door Bottom Auxiliary Sealing Strip Replacement (Impala and Monte Carlo Front) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the front door. 2. Remove the push-in retainers from the front door bottom auxiliary sealing strip using the J 38778 . 3. Remove the door bottom auxiliary sealing strip from the front door. Installation Procedure 1. Install the front door bottom auxiliary sealing strip to the front door. 2. Stretch the door bottom auxiliary sealing strip in order to align the push-in retainers to the holes in the front door. 3. Install the push-in retainers to the door bottom auxiliary sealingstrip. 4. Close the front door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Opening Weatherstrip Replacement > Page 11510 Front Door Weatherstrip: Service and Repair Sealing Strip Replacement - Front Door Window Belt Outer REMOVAL PROCEDURE 1. Remove the outside rearview mirror. 2. Remove the rear screw from the front door outer belt sealing strip. 3. Remove the front door outer belt sealing strip. INSTALLATION PROCEDURE 1. Position the front door outer belt sealing strip to the front door pinch-weld flange. 2. Install the front door outer belt sealing strip to the front door pinch-weld flange pressing into place until fully seated. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw to the rear of the front door outer belt sealing strip. Tighten Tighten the outer belt sealing strip screw to 2 N.m (18 lb in). 4. Install the outside rearview mirror. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window Front Door Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Window REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Remove the front door water deflector. 3. Remove the front door outer belt sealing strip. 4. Remove the front door window. 5. Remove the screws from the front door window channel. 6. Remove the front door window channel from the front door frame. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 11516 7. Remove the front door channel from the front door. 8. Remove the screw from the front door rear window channel. 9. Remove the front door rear window channel from the front door slot by pulling down to disengage the retainer clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 11517 10. Remove the front door rear window channel from the front door through the access hole in the inner front door panel. INSTALLATION PROCEDURE 1. Position the front door window channel front channel into the front door. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 11518 2. Install the front door window channel screws. Tighten Tighten the front door window channel screws to 10 N.m (89 lb in). 3. Install the front door window channel to the front door starting in the top corner working out in both directions. Firmly seat the front door window channel to the front door. 4. Install the front door rear window channel to the front door through the access hole in the inner front door panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 11519 5. Install the front door rear window channel to the front door slot by pushing up to engage the retainer clip. 6. Install the screw to the front door rear window channel. Tighten Tighten the front door weatherstrip channel screws to 10 N.m (89 lb in). 7. Install the front door window. 8. Inspect the front door window for proper operation. 9. Install the front door outer belt sealing strip. 10. Install the front door water deflector. 11. Install the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 11520 Front Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Front Side Door Window Weatherstrip Replacement (Impala) Removal Procedure 1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (Impala) See: Front Door Panel/Service and Repair 2. Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement (Impala) See: Front Door Panel/Service and Repair 3. Remove the front door outer belt sealing strip. Refer to Front Side Door Window Belt Outer Sealing Strip Replacement (Impala) (See: Door Window Sealing Strip). 4. Remove the front door window. Refer to Front Side Door Window Replacement (Impala) (See: Service and Repair/Front Side Door Window Replacement). 5. Remove the screws from the front door window channel. 6. Remove the front door window channel from the front door frame. 7. Remove the front door window channel from the front door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 11521 8. Remove the screw from the front door rear window channel. 9. Remove the front door rear window channel from the front door slot by pulling down to disengage the retainer clip. 10. Remove the front door rear window channel from the front door through the access hole in the inner front door panel. Installation Procedure 1. Position the front door window channel front channel into the front door. Notice: Refer to Fastener Notice in Cautions and Notices. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 11522 2. Install the front door window channel screws. Tighten the front door window channel screws to 10 Nm (89 lb in). 3. Install the front door window channel to the front door starting in the top corner working out in both directions. Firmly seat the front door window channel to the front door. 4. Install the front door rear window channel to the front door through the access hole in the inner front door panel. 5. Install the front door rear window channel to the front door slot by pushing up to engage the retainer clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 11523 6. Install the screw to the front door rear window channel. Tighten the front door weatherstrip channel screws to 10 Nm (89 lb in). 7. Install the front door window. Refer to Front Side Door Window Replacement (Impala) (See: Service and Repair/Front Side Door Window Replacement). 8. Inspect the front door window for proper operation. 9. Install the front door outer belt sealing strip. Refer to Front Side Door Window Belt Outer Sealing Strip Replacement (Impala) (See: Door Window Sealing Strip). 10. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement (Impala) See: Front Door Panel/Service and Repair 11. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (Impala) See: Front Door Panel/Service and Repair Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 11524 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Front Side Door Window Belt Outer Sealing Strip Replacement (Impala) Removal Procedure 1. Remove the outside rearview mirror. Refer to Power Mirror Replacement (Impala) (See: Mirrors/Service and Repair/Power Mirror Replacement ). 2. Remove the rear screw from the front door outer belt sealing strip. 3. Remove the front door outer belt sealing strip. Installation Procedure 1. Position the front door outer belt sealing strip to the front door pinch-weld flange. 2. Install the front door outer belt sealing strip to the front door pinch-weld flange pressing into place until fully seated. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screw to the rear of the front door outer belt sealing strip. Tighten the outer belt sealing strip screw to 2 Nm (18 lb in). 4. Install the outside rearview mirror. Refer to Power Mirror Replacement (Impala) (See: Mirrors/Service and Repair/Power Mirror Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair Front Side Door Window Regulator Motor Replacement Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Replacement (Impala) Removal Procedure 1. Position the front door window with a 6.3 mm (1/4 in) space at the top. 2. Tape the window to the window frame. 3. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (Impala) See: Front Door Panel/Service and Repair 4. Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement (Impala) See: Front Door Panel/Service and Repair 5. Disconnect the front window from the front window regulator carrier plate. Refer to Front Side Door Window Replacement (Impala) (See: Front Door Window Glass/Service and Repair/Front Side Door Window Replacement). 6. Disconnect the electrical connector from the front window regulator motor. 7. Loosen the bolts on the front window regulator motor. 8. Loosen the top bolts and remove the lower bolts on the front window regulator rail. 9. Remove the front window regulator, lifting up and out from the key slots on the front door inner panel and through the rear access hole. Installation Procedure 1. Install the top window regulator bolts half way into the window regulator motor and the rail. 2. Position the front window regulator rail through the rear access hole first. 3. Position the front window regulator motor through the rear access hole. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 11531 Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the front window regulator bolts into the key slots. Tighten the front window regulator motor and the rail bolts to 10 Nm (89 lb in). 5. Remove the tape from the front window and position the front window to the front window regulator carrier plate. 6. Connect the front window to the front window regulator carrier plate. Refer to Front Side Door Window Replacement (Impala) (See: Front Door Window Glass/Service and Repair/Front Side Door Window Replacement). 7. Connect the electrical connector to the front window regulator motor. 8. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement (Impala) See: Front Door Panel/Service and Repair 9. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (Impala) See: Front Door Panel/Service and Repair Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair Rear Side Door Outside Handle Replacement Removal Procedure The outside handles have adjustable outside handle-to-lock rods. This allows for adjustment of the amount of effort needed to operate the outside handle. When servicing a vehicle with adjustable outside handle-to-lock rods, it is important that all free play between the outside handle and the lock be removed. Do not operate the outside handle before these connections are made. 1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement See: Rear Door Panel/Service and Repair 2. Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (Impala) (See: Rear Door Panel/Service and Repair ). 3. Unsnap the clip from the outside handle rod and discard the rod-to-lock clip. 4. Remove the rear door outside door handle bolt access plug. 5. Remove the rear door outside door handle bolts (3). 6. Remove the rear door outside door handle with the handle rod from the door. 7. Separate the handle rod from the outside door handle. Installation Procedure 1. Position the rear door outside door handle and the handle rod to the rear door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Page 11537 Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the rear door outside door handle bolts (3). Tighten the rear door outside door handle bolts to 10 Nm (89 lb in). 3. Install the rear door outside door handle bolt access plug. 4. Install a NEW outside handle rod-to-lock clip onto the door lock lever. 1. Position the outside door handle rod in the clip to eliminate any free play in the outside door handle. 2. Install the clip cover closed over threaded outside door handle rod. 5. Install the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (Impala) (See: Rear Door Panel/Service and Repair). 6. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement See: Rear Door Panel/Service and Repair Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Rear Side Door Inside Handle Replacement Rear Door Interior Handle: Service and Repair Rear Side Door Inside Handle Replacement Rear Side Door Inside Handle Replacement (Impala) Removal Procedure 1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement See: Rear Door Panel/Service and Repair 2. Remove the rear door water deflector from the rear inside door handle. Refer to Rear Side Door Water Deflector Replacement (Impala) (See: Rear Door Panel/Service and Repair). 3. Drill out the rivet (2) from the rear inside door handle using a 6.35 mm (1/4 in) drill bit. 4. Remove the lock rod and door handle rod from the rear inside door handle. 5. Remove the rear inside door handle from the rear door inner panel. Installation Procedure 1. Install the rear inside door handle by inserting the tabs into the rear door inner panel slots. 2. Install the lock rod and the door handle rod to the rear inside door handle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Rear Side Door Inside Handle Replacement > Page 11542 3. Install the rivet (2) to the rear inside door handle. 4. Install the water deflector to the rear inside door handle. Refer to Rear Side Door Water Deflector Replacement (Impala) (See: Rear Door Panel/Service and Repair). 5. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement See: Rear Door Panel/Service and Repair Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Rear Side Door Inside Handle Replacement > Page 11543 Rear Door Interior Handle: Service and Repair Rear Side Door Inside Handle Rod Replacement Rear Side Door Inside Handle Rod Replacement (Impala) Removal Procedure 1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement See: Rear Door Panel/Service and Repair 2. Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (Impala) (See: Rear Door Panel/Service and Repair ). 3. Remove the rear door inside handle rod from the rear door inside door handle (4). 4. Remove the rear door inside handle rod from the retainer clip (4). 5. Remove the rear door inside handle rods from the door lock (6). Installation Procedure 1. Install the inside handle rod to the door lock (6). 2. Push in the rear door handle rod in order to secure it. 3. Install the rear door inside handle to the retainer clip (4). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Rear Side Door Inside Handle Replacement > Page 11544 4. Install the rear door inside handle rod to the rear door inside door handle. 5. Secure the rear door inside handle rod with a clip. 6. Install the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (Impala) (See: Rear Door Panel/Service and Repair). 7. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement See: Rear Door Panel/Service and Repair Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair Rear Door Hinge: Service and Repair Door Hinge Replacement (Impala Rear) Removal Procedure Important: This procedure is completed with the rear door closed at all times. Do each door hinge separately, and replace the broken door hinge first. 1. Open the front door in order to remove the rear door hinges. 2. Clean the mounting surfaces with clean a rag and mark the rear door hinge locations on each surface with a grease pencil or other suitable marker. 3. Remove the bolts from the doorside rear door hinge. 4. Remove the bolts (1-5) from the bodyside rear door hinge. 5. Remove the rear door hinge from the vehicle. Installation Procedure 1. Position the rear door hinge to the alignment marks. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts (1-5) to the bodyside rear door hinge. Tighten the bodyside rear door hinge bolts to 33 Nm (24 lb ft). 3. Install the bolts to the doorside rear door hinge. Tighten the doorside rear door hinge bolts to 33 Nm (24 lb ft). 4. Close the rear door. 5. Inspect the rear door for proper operation and Alignment. Refer to Door Adjustment (Rear) (See: Adjustments)Door Adjustment (Front) (See: Front Door/Adjustments). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement Rear Door Panel: Service and Repair Panel Replacement Rear Side Door Trim Panel Replacement Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Remove the rear door handle trim bezel. Refer to Door Inside Handle Bezel Replacement (Impala) (See: Front Door/Front Door Panel/Service and Repair/Door Inside Handle Bezel Replacement)Door Inside Handle Bezel Replacement (Monte Carlo) (See: Front Door/Front Door Panel/Service and Repair/Door Inside Handle Bezel Replacement). 2. Remove the rear door pull cup. Refer to Armrest Pull Cup Replacement (Impala) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Removal and Replacement/Armrest Pull Cup Replacement)Armrest Pull Cup Replacement (Monte Carlo) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Removal and Replacement/Armrest Pull Cup Replacement). 3. Remove the screws from the pull cup bracket. 4. Remove the rear door trim panel using J 38778 to disengage the fasteners from the door inner panel. 5. Disconnect and reposition the electrical connectors. 6. Remove the rear door trim panel from the vehicle. Installation Procedure Important: Before installing the rear door trim panel to the rear door inner panel, the old trim panel retainers MUST be discarded and replaced with NEW trim panel retainers. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 11552 1. Install the new trim panel retainers to the rear door trim panel. 2. Connect and route the electrical connectors through the openings in the rear door trim panel. 3. Align the rear door trim panel to the rear door inner panel, guiding the rear door handle through the trim panel. 4. Install the upper edge of the rear door trim panel to the top edge of the inner door panel, pressing down firmly until the retainer clips are fully seated. 5. Align the two locator pins on the rear door trim panel to the front door inner panel. 6. Install the rear door trim panel pressing firmly until the retainer clips are fully seated around the perimeter of the trim panel. Notice: Refer to Fastener Notice in Cautions and Notices. 7. Install the screws to the pull cup bracket. Tighten the screws to the pull cup bracket to 6 Nm (53 lb in). 8. Install the rear door handle trim bezel. Refer to Door Inside Handle Bezel Replacement (Impala) (See: Front Door/Front Door Panel/Service and Repair/Door Inside Handle Bezel Replacement)Door Inside Handle Bezel Replacement (Monte Carlo) (See: Front Door/Front Door Panel/Service and Repair/Door Inside Handle Bezel Replacement). 9. Install the rear door switch plate. Refer to Armrest Pull Cup Replacement (Impala) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Removal and Replacement/Armrest Pull Cup Replacement)Armrest Pull Cup Replacement (Monte Carlo) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Removal and Replacement/Armrest Pull Cup Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 11553 Rear Door Panel: Service and Repair Energy Absorber Pad Replacement Energy Absorber Pad Replacement - Outer Rear REMOVAL PROCEDURE CAUTION: This vehicle has energy-absorbing foam blocks for side impact protection. To help avoid personal injury in a collision, foam blocks that are damaged, or removed during repairs must be replaced. Failure to replace foam blocks that are removed can violate federal law. 1. Open the rear door. 2. Remove the rear door trim panel. 3. Remove the rear door water deflector. 4. Remove the rear door energy absorber pad screw and clip from the rear door. 5. Grasp the energy absorber with both hands and pull it away from the door. If necessary, warm the outer door panel to soften the adhesive. 6. Use a rag and alcohol to clean the adhesive off the door panel. INSTALLATION PROCEDURE 1. Remove the double backed tape protective backing from the rear door outer energy absorber pad. 2. Install the rear door outer energy absorber pad to the rear door. 3. Install the clip and screw to the rear door outer energy absorber pad. 4. Install the rear door water deflector. 5. Install the rear door trim panel. 6. Close the rear door. Outer Rear Energy Absorber Pad Replacement Outer Rear Energy Absorber Pad Replacement Removal Procedure Caution: This vehicle has energy-absorbing foam blocks for side impact protection. To help avoid personal injury in a collision, foam blocks that are damaged, or removed during repairs must be replaced. Failure to replace foam blocks that are removed can violate federal law. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 11554 1. Open the rear door. 2. Remove the rear door trim panel. 3. Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (Impala) (See: ). 4. Remove the rear door energy absorber pad screw and clip from the rear door. 5. Grasp the energy absorber with both hands and pull it away from the door. If necessary, warm the outer door panel to soften the adhesive. 6. Use a rag and alcohol to clean the adhesive off the door panel. Installation Procedure 1. Remove the double backed tape protective backing from the rear door outer energy absorber pad. 2. Install the rear door outer energy absorber pad to the rear door. 3. Install the clip and screw to the rear door outer energy absorber pad. 4. Install the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (Impala) (See: ). 5. Install the rear door trim panel. 6. Close the rear door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 11555 Rear Door Panel: Service and Repair Water Deflector Rear Side Door Water Deflector Replacement (Impala) Removal Procedure 1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement. 2. Remove the rear door pull handle bracket from the rear door inner panel. 3. Disconnect all of the required electrical connectors. 4. Remove the inside door handle gasket. 5. Remove the rear door water deflector from the rear door inner panel. Installation Procedure 1. Align the rear door water deflector to the rear door inner panel. Secure the water deflector at the corners. 2. Pull the rear door wiring harness leads through the slits in the rear door water deflector. 3. Install the rear door water deflector, start pressing the adhesive pattern at the bottom center and working outward and upward in order to prevent puckering. 4. Install the inside door handle gasket. 5. Connect all of the required electrical connectors. 6. Install the rear door pull handle bracket to the rear door inner panel. 7. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 11556 Rear Door Panel: Service and Repair Reflector Replacement Rear Side Door Warning Reflector Replacement (Impala) Removal Procedure 1. Open the rear door. 2. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement. Grind off the tabs which were melted to hold the reflector in place. 3. Remove the warning reflector from the rear door inner trim panel. Installation Procedure 1. Install the warning reflector into the trim panel, pressing into place until fully seated. 2. Melt the tabs to hold the reflector in place. 3. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement. 4. Close the rear door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments > Door Lock Striker Adjustment (With Mini Wedge) Rear Door Striker: Adjustments Door Lock Striker Adjustment (With Mini Wedge) Door Lock Striker Adjustment (With Mini Wedge) Tools Required J 39346-A Mini Wedge Door Striker Aligner Important: Properly align the door before adjusting the striker. 1. Open the door. 2. Loosen the door striker screws just enough to allow movement of the door striker. 3. Install the J 39346-A . Important: Do not slam the door. 4. Close the door while holding the outside handle in the open position. 5. Open the door. Notice: Refer to Fastener Notice in Cautions and Notices. 6. Tighten the door lock striker screws. Tighten the door striker screws to 25 Nm (18 lb ft). 7. Remove the J 39346-A . 8. Close the door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments > Door Lock Striker Adjustment (With Mini Wedge) > Page 11561 Rear Door Striker: Adjustments Door Lock Striker Adjustment (With Clay or Caulk) Door Lock Striker Adjustment (With Clay or Caulk) Important: Properly align the door before adjusting the striker. 1. Open the door. 2. Loosen the door striker screws just enough to allow movement of the door striker. 3. Adjust the door striker up or down and inboard or outboard as required. 4. Apply modeling clay or body caulking compound to the door lock opening. Important: Do not close the door all the way. 5. Close the door far enough for the striker to make an impression into the modeling clay or body caulking compound. 6. Open the door and check the door striker impression in the modeling clay or body caulking compound. Notice: Refer to Fastener Notice in Cautions and Notices. 7. Readjust door striker as required. Add or remove spacers as needed. Tighten the door striker screws to 25 Nm (18 lb ft). 8. Close the door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door REMOVAL PROCEDURE 1. Open the rear door. 2. Remove the trim panels. 3. Remove the weatherstrip from the rear door opening by pulling the weatherstrip off the pinchweld flange. INSTALLATION PROCEDURE 1. Position the rear door opening weatherstrip to the pinchweld flange. Starting at the center of the rocker panel area and moving in a clockwise direction, press the weatherstrip to the pinchweld flange until fully seated. IMPORTANT: The joint butt ends must have no gap and must be located in the center of the of the rocker panel area. 2. Install the joint butt ends together. 3. Install the trim panels. 4. Close the rear door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 11566 Rear Door Weatherstrip: Service and Repair Door Bottom Auxiliary Sealing Strip Replacement (Rear) Door Bottom Auxiliary Sealing Strip Replacement (Impala Rear) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the rear door. 2. Remove the push-in retainers from the rear door bottom auxiliary sealingstrip using the J 38778 . 3. Remove the door bottom auxiliary sealingstrip from the rear door. Installation Procedure 1. Position the door bottom auxiliary weatherstrip to the rear door. 2. Stretch the door bottom auxiliary weatherstrip in order to align the push-in retainers to the holes in the door. 3. Install the push-in retainers to the door bottom auxiliary weatherstrip. 4. Close the rear door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 11567 Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement Rear Door Opening Weatherstrip Replacement (Impala) Removal Procedure 1. Open the rear door. 2. Remove the carpet retainers. Refer to Rear Side Door Opening Floor Carpet Retainer Replacement (See: Interior Moulding / Trim/Carpet/Service and Repair/Rear Side Door Opening Floor Carpet Retainer Replacement) in Interior Trim. 3. Remove the rear quarter upper trim panel. Refer to Quarter Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Upper Trim Panel Replacement) in Interior Trim. 4. Remove the rear quarter lower trim panel. Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Lower Rear Trim Panel Replacement) in Interior Trim. 5. Remove the upper center pillar trim panel. Refer to Center Pillar Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Trim Panel Replacement) in Interior Trim. 6. Remove the center lower trim panel. Refer to Center Pillar Lower Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Lower Trim Panel Replacement) in Interior Trim. 7. Remove the rear door opening weatherstrip by pulling it off the pinchweld flange. Installation Procedure 1. Position the rear door opening weatherstrip to the pinchweld flange. Starting at the center of the rocker panel area and moving in a clockwise direction press the rear door opening weatherstrip to the pinchweld flange until fully seated. Important: The joint butt ends must have no gap and be located in the center of the of the rocker panel area. 2. Install joint butt ends together. 3. Install the rear quarter upper trim panel. Refer to Quarter Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Upper Trim Panel Replacement) in Interior Trim. 4. Install the rear quarter lower trim panel. Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Lower Rear Trim Panel Replacement) in Interior Trim. 5. Install the upper center pillar trim panel. Refer to Center Pillar Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Trim Panel Replacement) in Interior Trim. 6. Install the center lower trim panel. Refer to Center Pillar Lower Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Lower Trim Panel Replacement) in Interior Trim. 7. Install the carpet retainers. Refer to Rear Side Door Opening Floor Carpet Retainer Replacement (See: Interior Moulding / Trim/Carpet/Service Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 11568 and Repair/Rear Side Door Opening Floor Carpet Retainer Replacement) in Interior Trim. 8. Close the rear door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 11569 Rear Door Weatherstrip: Service and Repair Rear Side Door Window Outer Sealing Strip Replacement Rear Side Door Window Outer Sealing Strip Replacement (Impala) Removal Procedure 1. Position the rear window all the way down. 2. Remove the rear door trim panel to have access to these screws. Refer to Rear Side Door Trim Panel Replacement See: Rear Door Panel/Service and Repair 3. Remove the rear door outer belt sealing strip screws. 4. Remove the rear window outer belt sealing strip by pulling the sealing strip from the rear door pinch-weld flange. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 11570 1. Position the rear door outer belt sealing strip to the rear door pinch-weld flange. 2. Install the rear door outer belt sealing strip to the pinch-weld flange, pressing into place until full seated. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the rear door outer belt sealing strip screws. Tighten the rear door outer belt sealing strip screws to 2 Nm (18 lb in). 4. Install Rear door trim panel. Refer to Rear Side Door Trim Panel Replacement See: Rear Door Panel/Service and Repair Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 11571 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door REMOVAL PROCEDURE 1. Open the rear door. 2. Remove the trim panels. 3. Remove the weatherstrip from the rear door opening by pulling the weatherstrip off the pinchweld flange. INSTALLATION PROCEDURE 1. Position the rear door opening weatherstrip to the pinchweld flange. Starting at the center of the rocker panel area and moving in a clockwise direction, press the weatherstrip to the pinchweld flange until fully seated. IMPORTANT: The joint butt ends must have no gap and must be located in the center of the of the rocker panel area. 2. Install the joint butt ends together. 3. Install the trim panels. 4. Close the rear door. Door Bottom Auxiliary Sealing Strip Replacement (Rear) Door Bottom Auxiliary Sealing Strip Replacement (Impala Rear) Tools Required Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 11572 J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the rear door. 2. Remove the push-in retainers from the rear door bottom auxiliary sealingstrip using the J 38778 . 3. Remove the door bottom auxiliary sealingstrip from the rear door. Installation Procedure 1. Position the door bottom auxiliary weatherstrip to the rear door. 2. Stretch the door bottom auxiliary weatherstrip in order to align the push-in retainers to the holes in the door. 3. Install the push-in retainers to the door bottom auxiliary weatherstrip. 4. Close the rear door. Rear Door Opening Weatherstrip Replacement Rear Door Opening Weatherstrip Replacement (Impala) Removal Procedure 1. Open the rear door. 2. Remove the carpet retainers. Refer to Rear Side Door Opening Floor Carpet Retainer Replacement (See: Interior Moulding / Trim/Carpet/Service and Repair/Rear Side Door Opening Floor Carpet Retainer Replacement) in Interior Trim. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 11573 3. Remove the rear quarter upper trim panel. Refer to Quarter Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Upper Trim Panel Replacement) in Interior Trim. 4. Remove the rear quarter lower trim panel. Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Lower Rear Trim Panel Replacement) in Interior Trim. 5. Remove the upper center pillar trim panel. Refer to Center Pillar Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Trim Panel Replacement) in Interior Trim. 6. Remove the center lower trim panel. Refer to Center Pillar Lower Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Lower Trim Panel Replacement) in Interior Trim. 7. Remove the rear door opening weatherstrip by pulling it off the pinchweld flange. Installation Procedure 1. Position the rear door opening weatherstrip to the pinchweld flange. Starting at the center of the rocker panel area and moving in a clockwise direction press the rear door opening weatherstrip to the pinchweld flange until fully seated. Important: The joint butt ends must have no gap and be located in the center of the of the rocker panel area. 2. Install joint butt ends together. 3. Install the rear quarter upper trim panel. Refer to Quarter Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Upper Trim Panel Replacement) in Interior Trim. 4. Install the rear quarter lower trim panel. Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Lower Rear Trim Panel Replacement) in Interior Trim. 5. Install the upper center pillar trim panel. Refer to Center Pillar Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Trim Panel Replacement) in Interior Trim. 6. Install the center lower trim panel. Refer to Center Pillar Lower Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Lower Trim Panel Replacement) in Interior Trim. 7. Install the carpet retainers. Refer to Rear Side Door Opening Floor Carpet Retainer Replacement (See: Interior Moulding / Trim/Carpet/Service and Repair/Rear Side Door Opening Floor Carpet Retainer Replacement) in Interior Trim. 8. Close the rear door. Rear Side Door Window Outer Sealing Strip Replacement Rear Side Door Window Outer Sealing Strip Replacement (Impala) Removal Procedure 1. Position the rear window all the way down. 2. Remove the rear door trim panel to have access to these screws. Refer to Rear Side Door Trim Panel Replacement See: Rear Door Panel/Service Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 11574 and Repair 3. Remove the rear door outer belt sealing strip screws. 4. Remove the rear window outer belt sealing strip by pulling the sealing strip from the rear door pinch-weld flange. Installation Procedure 1. Position the rear door outer belt sealing strip to the rear door pinch-weld flange. 2. Install the rear door outer belt sealing strip to the pinch-weld flange, pressing into place until full seated. Notice: Refer to Fastener Notice in Cautions and Notices. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 11575 3. Install the rear door outer belt sealing strip screws. Tighten the rear door outer belt sealing strip screws to 2 Nm (18 lb in). 4. Install Rear door trim panel. Refer to Rear Side Door Trim Panel Replacement See: Rear Door Panel/Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement TOOLS REQUIRED J 38778 Door Trim Pad Clip Remover REMOVAL PROCEDURE 1. Open the rear door. 2. Remove the push-in retainers from the rear door bottom auxiliary sealingstrip using the J 38778. 3. Remove the door bottom auxiliary sealingstrip from the rear door. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 11576 1. Position the door bottom auxiliary weatherstrip to the rear door. 2. Stretch the door bottom auxiliary weatherstrip in order to align the push-in retainers to the holes in the door. 3. Install the push-in retainers to the door bottom auxiliary weatherstrip. 4. Close the rear door. Sealing Strip Replacement - Door Bottom - Rear TOOLS REQUIRED J 38778 Door Trim Pad Clip Remover REMOVAL PROCEDURE 1. Open the rear door. 2. Remove the push-in retainers from the rear door bottom auxiliary sealingstrip using the J 38778. 3. Remove the door bottom auxiliary sealingstrip from the rear door. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 11577 1. Position the door bottom auxiliary weatherstrip to the rear door. 2. Stretch the door bottom auxiliary weatherstrip in order to align the push-in retainers to the holes in the door. 3. Install the push-in retainers to the door bottom auxiliary weatherstrip. 4. Close the rear door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window Rear Door Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door Window REMOVAL PROCEDURE 1. Place the rear window in the full down position. 2. Remove the rear door trim panel. 3. Remove the outer belt sealing strip. 4. Remove the rear window channel from the door. INSTALLATION PROCEDURE 1. Position the rear window channel to the rear door starting in the corner.Work outward in both directions. 2. Firmly seat the rear window channel to the rear door. 3. Inspect the rear door window for proper operation. 4. Install the outer belt sealing strip. 5. Install the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 11583 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Channel Rear Side Door Window Channel Retainer Replacement (Impala) Removal Procedure 1. Partially remove the upper portion of the rear door frame appliques. Refer to Rear Door Frame Applique Replacement (Impala Front) ()Rear Door Frame Applique Replacement (Impala Rear) (). 2. Pull downwards on the rear door window channel to gain access to the rivets. 3. Drill out the rivets. 4. Remove the forward screw to the rear window channel retainer. 5. Remove the rear window channel retainer from the rear door. Installation Procedure 1. Position the rear window weatherstrip retainer. 2. Push downwards on the rear door window channel to gain access to the rivets holes. 3. Install weather strip retainer rivets. 4. Install the rear door frame applique. Refer to Rear Door Frame Applique Replacement (Impala Front) ()Rear Door Frame Applique Replacement (Impala Rear) (). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 11584 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Rear Side Door Window Weatherstrip Replacement (Impala) Removal Procedure 1. Place the rear window in the full down position. 2. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement See: Rear Door Panel/Service and Repair 3. Remove the outer belt sealing strip. Refer to Rear Side Door Window Outer Sealing Strip Replacement (Impala) (See: Rear Door Weatherstrip/Service and Repair/Rear Side Door Window Outer Sealing Strip Replacement). 4. Remove the rear window channel from the door. Installation Procedure 1. Position the rear window channel to the rear door starting in the corner. Work outward in both directions. 2. Firmly seat the rear window channel to the rear door. 3. Inspect the rear door window for proper operation. 4. Install the outer belt sealing strip. Refer to Rear Side Door Window Outer Sealing Strip Replacement (Impala) (See: Rear Door Weatherstrip/Service and Repair/Rear Side Door Window Outer Sealing Strip Replacement). 5. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement See: Rear Door Panel/Service and Repair Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 11585 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip REMOVAL PROCEDURE 1. Position the rear window all the way down. 2. Remove the rear door trim panel to have access to these screws. 3. Remove the rear door outer belt sealing strip screws. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 11586 4. Remove the rear window outer belt sealing strip by pulling the sealing strip from the rear door pinch-weld flange. INSTALLATION PROCEDURE 1. Position the rear door outer belt sealing strip to the rear door pinch-weld flange. 2. Install the rear door outer belt sealing strip to the pinch-weld flange, pressing into place until full seated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 11587 NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the rear door outer belt sealing strip screws. Tighten Tighten the rear door outer belt sealing strip screws to 1.5 N.m (13 lb in). 4. Install Rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair Rear Door Window Motor: Service and Repair Rear Side Door Window Regulator Motor Replacement Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Impala) Removal Procedure 1. Position the front door window with a 6.3 mm (1/4 in) space at the top. 2. Tape the window to the window frame. 3. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement See: Rear Door Panel/Service and Repair. 4. Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (Impala) (See: Rear Door Panel/Service and Repair ). 5. Disconnect the rear window from the rear window regulator carrier plate. Refer to Rear Side Door Window Replacement (Impala) (See: Rear Door Window Glass/Service and Repair). 6. Disconnect the electrical connector from the rear window regulator motor. 7. Loosen the bolts on the rear window regulator motor. 8. Loosen the bolts on the rear window regulator rail. 9. Remove the rear window regulator, lifting up and out from the key slots on the rear door inner panel and through the rear access hole. Installation Procedure 1. Install the rear window regulator bolts half way into the rear window regulator motor and the rail. 2. Position the rear window regulator rail through the rear access hole first. 3. Position the rear window regulator motor through the rear access hole. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 11594 Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the rear window regulator into the key slots. Tighten the rear window regulator motor and the rail bolts to 10 Nm (89 lb in). 5. Remove the tape from the rear window and position the rear window to the rear window regulator carrier plate. 6. Connect the rear window to the rear window regulator carrier plate. Refer to Rear Side Door Window Replacement (Impala) (See: Rear Door Window Glass/Service and Repair). 7. Connect the electrical connector to the rear window regulator motor. 8. Install the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (Impala) (See: Rear Door Panel/Service and Repair). 9. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement See: Rear Door Panel/Service and Repair Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair Fuel Door: Service and Repair Fuel Tank Filler Door Replacement (Impala) Removal Procedure 1. Open the fuel filler door. 2. Drill out the rivets from the fuel filler door. 3. Remove the fuel filler door from the quarter panel. Installation Procedure 1. Align the fuel filler door to the holes in the quarter panel. 2. Install the fuel filler door to the quarter panel using new rivets. 3. Close the fuel filler door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Procedures Hood Hinge: Procedures HOOD HINGE REPLACEMENT Removal Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Remove the hood. 2. Remove the hood rear side seal. 3. Remove the hood assist rod. 4. Loosen the hood hinge to fender bolts, but do not remove the bolts. 5. Center punch the spot weld. 6. Drill out the spot weld using a 9.5 mm (3/8 in) drill bit. 7. Remove the hood hinge to fender bolts. 8. Remove the hood hinge from the fender. 9. Repair the paint on the fender where the hood hinge was removed. Installation Important: Weld on body side is an assembly plant assembly aid only. Weld is not required when installing a replacement hinge. 1. Align the hood hinge to the fender. Note: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 2. Install the hood hinge to fender bolts. Tighten Tighten the hood hinge to fender bolts to 25 Nm (18 lb ft). 3. Install the hood. 4. Install the hood assist rod. 5. Install the hood rear side seal. 6. Adjust the hood, as required. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Procedures > Page 11603 Hood Hinge: Removal and Replacement Hood Hinge Replacement Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Remove the hood. Refer to Hood Replacement (See: Service and Repair). 2. Remove the hood rear side seal. Refer to Hood Rear Outer Seal Replacement (See: Hood Weatherstrip/Service and Repair/Hood Rear Outer Seal Replacement). 3. Remove the hood assist rod. Refer to Hood Open Assist Rod Replacement (See: Hood Shock / Support/Service and Repair). 4. Loosen the hood hinge to fender bolts, but do not remove the bolts. 5. Center punch the spot weld. 6. Drill out the spot weld using a 9.5 mm (3/8 in) drill bit. 7. Remove the hood hinge to fender bolts. 8. Remove the hood hinge from the fender. 9. Repair the paint on the fender where the hood hinge was removed. Refer to Anti-Corrosion Treatment and Repair (). Installation Procedure Important: Weld on body side is an assembly plant assembly aid only. Weld is not required when installing a replacement hinge. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Procedures > Page 11604 1. Align the hood hinge to the fender. Notice: Refer to Fastener Notice . 2. Install the hood hinge to fender bolts. Tighten the hood hinge to fender bolts to 25 Nm (18 lb ft). 3. Install the hood. Refer to Hood Replacement (See: Service and Repair). 4. Install the hood assist rod. Refer to Hood Open Assist Rod Replacement (See: Hood Shock / Support/Service and Repair). 5. Install the hood rear side seal. Refer to Hood Rear Outer Seal Replacement (See: Hood Weatherstrip/Service and Repair/Hood Rear Outer Seal Replacement). 6. Adjust the hood, as required. Refer to Hood Adjustment (See: Adjustments). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Insulator / Pad > Component Information > Service and Repair Hood Insulator / Pad: Service and Repair Hood Insulator Replacement Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the hood. 2. Use J 38778 to remove the hood insulator push-in retainers. 3. Remove the hood insulator from the hood. Installation Procedure 1. Install the hood insulator to the hood support brackets. 2. Align the hood insulator retainers holes to the holes in the hood. 3. Install the push-in retainers to the hood. 4. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Support Replacement Hood Latch: Service and Repair Hood Latch Support Replacement Hood Latch Support Replacement Removal Procedure 1. Open the hood. 2. Remove upper radiator air baffle. Refer to Radiator Air Baffle Assemblies and Deflectors (Upper) Radiator Air Baffle Assemblies and Deflectors (Side) Radiator Air Baffle Assemblies and Deflectors (Lower) in Engine Cooling. 3. Remove the hood latch from the hood latch support. Refer to Hood Primary and Secondary Latch Replacement (See: Hood Primary and Secondary Latch Replacement). 4. Remove the bolts from the front bumper fascia upper support bracket. Refer to Front Bumper Fascia Upper Support Replacement (Impala) (See: Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Upper Support Replacement)Front Bumper Fascia Upper Support Replacement (Monte Carlo) (See: Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Upper Support Replacement) in Bumpers. 5. Remove the bolts from the hood latch support at the upper tie bar. 6. Remove the nut from the hood latch support at the lower tie bar. 7. Remove the hood latch support from the vehicle. Installation Procedure 1. Install the hood latch support to the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Support Replacement > Page 11612 Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts to the hood latch support at the upper tie bar. Tighten the hood latch support bolts to 25 Nm (18 lb ft). 3. Install the nut to the hood latch support at the lower tie bar. Tighten the hood latch support nut to 10 Nm (89 lb in). 4. Install the bolts to the front bumper fascia upper support bracket. Refer to Front Bumper Fascia Upper Support Replacement (Impala) (See: Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Upper Support Replacement)Front Bumper Fascia Upper Support Replacement (Monte Carlo) (See: Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Upper Support Replacement) in Bumpers. 5. Install the hood latch to the hood latch support. Refer to Hood Primary and Secondary Latch Replacement (See: Hood Primary and Secondary Latch Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Support Replacement > Page 11613 Hood Latch: Service and Repair Hood Primary and Secondary Latch Replacement Hood Primary and Secondary Latch Replacement Removal Procedure 1. Open the hood. 2. Remove the upper radiator air baffle. Refer to Radiator Air Baffle Assemblies and Deflectors (Upper) Radiator Air Baffle Assemblies and Deflectors (Side) Radiator Air Baffle Assemblies and Deflectors (Lower) in Engine Cooling. 3. Remove the front upper fascia support bracket. Refer to Front Upper Fascia Support Bracket Replacement (See: Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Upper Fascia Support Bracket Replacement) in Bumpers. 4. Mark the hood latch to the center support bracket with a grease pencil. 5. Remove the bolts from the hood latch. Important: Do not crimp the hood release cable. 6. Remove the hood release cable from the hood latch by squeezing the cable retainer. 7. Remove the hood latch from the vehicle. Installation Procedure 1. Install the hood release cable to the hood latch. 2. Align the hood latch to the marks on the center support bracket. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Support Replacement > Page 11614 Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the hood latch to center support bolts. Tighten the Hood Latch to Center Support Bolts to 10 Nm (89 lb in). 4. Install the front upper fascia support bracket. Refer to Front Upper Fascia Support Bracket Replacement (See: Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Upper Fascia Support Bracket Replacement) in Bumpers. 5. Install the upper radiator air baffle. Refer to Radiator Air Baffle Assemblies and Deflectors (Upper) Radiator Air Baffle Assemblies and Deflectors (Side) Radiator Air Baffle Assemblies and Deflectors (Lower) in Engine Cooling. 6. Adjust the hood, if required. Refer to Hood Adjustment (See: Adjustments). 7. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Primary Latch Release Cable Handle Replacement Hood Latch Release Cable: Service and Repair Hood Primary Latch Release Cable Handle Replacement Hood Primary Latch Release Cable Handle Replacement Removal Procedure 1. Remove the left instrument panel insulator. Refer to Instrument Panel Insulator Replacement (Left) (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement (Left))Instrument Panel Insulator Replacement (Right) (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement (Right)) in Instrument Panel, Gages, and Console. 2. Remove the bolts from the hood release handle base. 3. Remove the hood release cable from the hood release handle. 4. Remove the hood release handle from the instrument panel. Installation Procedure 1. Install the hood release cable to the hood release handle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Primary Latch Release Cable Handle Replacement > Page 11619 2. Install the hood release handle to the instrument panel. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the bolts to hood release handle base. Tighten the hood release handle bolts to 2 Nm (18 lb in). 4. Install the left instrument panel insulator. Refer to Instrument Panel Insulator Replacement (Left) (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement (Left))Instrument Panel Insulator Replacement (Right) (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement (Right)) in Instrument Panel, Gages, and Console. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Primary Latch Release Cable Handle Replacement > Page 11620 Hood Latch Release Cable: Service and Repair Hood Primary Latch Release Cable Replacement Hood Primary Latch Release Cable Replacement Removal Procedure 1. Open the hood. 2. Block the hood latch to prevent the hood locking until the hood release cable has been installed. 3. Disconnect the hood release cable from the hood latch by squeezing the hood release cable retainer. 4. Remove hood release cable from the hood latch bracket. 5. Remove the air cleaner. * For the 3.4 L engine, refer to Air Cleaner Assembly Replacement in Engine Controls. * For the 3.8 L engine, refer to Air Cleaner Assembly Replacement in Engine Controls. 6. Remove the hood release cable retainers from the upper tie bar. 7. Remove the hood release cable retainers from the engine compartment side rail. 8. Remove the hood release cable from the hood release handle. Refer to Hood Primary Latch Release Cable Handle Replacement (See: Hood Primary Latch Release Cable Handle Replacement). 9. Pull the carpet back to access the hood release cable. Important: Ensure the end of the wire or string remains in the passenger compartment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Primary Latch Release Cable Handle Replacement > Page 11621 10. Tie the wire or string to the end of the hood release cable in order to aid in the installation of the new hood release cable. 11. Use a small, flat-bladed tool to remove the grommet from the dash. 12. Remove the hood release cable from the dash. 13. Remove the wire or string from the hood release cable. 14. Remove the hood release cable from the vehicle. Installation Procedure 1. Tie the wire or string to the hood release cable. 2. Install the hood release cable to the vehicle. 3. Pull the hood release cable through the dash until the grommet is seated in the hole. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Primary Latch Release Cable Handle Replacement > Page 11622 4. Install the grommet into the dash. 5. Install the hood release cable retainers to the engine compartment side rail. 6. Install the hood release cable retainers to the upper tie bar. 7. Connect the hood release cable to the hood latch. 8. Install the air cleaner. * For the 3.4 L engine, refer to Air Cleaner Assembly Replacement in Engine Controls. * For the 3.8 L engine, refer to Air Cleaner Assembly Replacement in Engine Controls. 9. Install the hood release cable to the hood release handle. Refer to Hood Primary Latch Release Cable Handle Replacement (See: Hood Primary Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Primary Latch Release Cable Handle Replacement > Page 11623 Latch Release Cable Handle Replacement). 10. Install the carpet back to its original position. 11. Remove the block from the hood latch. 12. Inspect the hood release cable for proper operation before closing the hood. 13. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair Hood Shock / Support: Service and Repair Hood Open Assist Rod Replacement Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Open and support the hood. 2. Lift up the retainer clips on the assist rod using a small flat-bladed tool. Notice: Refer to Liftgate/Hood Assist Rod Notice in Cautions and Notices. 3. Pull the upper end of the assist rod from the ball joint on the hood. 4. Pull the lower end of the assist rod from the ball joint on the lower hood hinge. Installation Procedure 1. Press the upper end of the assist rods on to the ball joint on the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair > Page 11627 2. Press the lower end of the assist rods on to the ball joint on the lower hood hinge 3. Remove the support from the hood. 4. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Stop > Component Information > Service and Repair Hood Stop: Service and Repair Hood Bumper Replacement Removal Procedure 1. Raise the hood. 2. Remove the hood bumper (1) from the vehicle by unscrewing the bumper (1) counterclockwise. Installation Procedure 1. Install the hood bumper (1) to the vehicle by screwing the bumper (1) clockwise into the vehicle. 2. Adjust the hood bumper (1) in order to ensure that the hood is flush with the front fender. 3. Lower the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement Hood Weatherstrip: Service and Repair Hood Front Seal Replacement Hood Front Seal Replacement Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the hood. 2. Use J 38778 to remove the push-in retainers from the front air seal. 3. Remove the front air seal from the hood. Installation Procedure 1. Install the front air seal to the hood. 2. Install the push-in retainers to the front air seal into the hood. 3. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement > Page 11635 Hood Weatherstrip: Service and Repair Hood Rear Seal Replacement Hood Rear Seal Replacement Removal Procedure 1. Open the hood. 2. Pull the hood rear weatherstrip from the pinch-weld flange. 3. Remove the hood rear weatherstrip from the vehicle. Installation Procedure 1. Install the hood rear weatherstrip to the pinch-weld flange. 2. Press the hood rear weatherstrip onto the pinch-weld flange. 3. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement > Page 11636 Hood Weatherstrip: Service and Repair Seal Replacement - Plenum to Hood Seal Replacement - Plenum to Hood Removal Procedure 1. Open the hood. 2. Remove the right side of the air inlet grille. Refer to Air Inlet Grille Panel Replacement (See: Cowl/Cowl Moulding / Trim/Service and Repair/Air Inlet Grille Panel Replacement). 3. To remove the seal from the pinch-weld flange, start at the passenger side corner of the seal and pull forward and off of the pinch-weld flange. Installation Procedure 1. Align the seal to the pinch-weld flange. 2. Press to install the seal to the pinch-weld flange, start at the passenger side corner and work toward the center of the car. 3. Install the right side of the air inlet grille. Refer to Air Inlet Grille Panel Replacement (See: Cowl/Cowl Moulding / Trim/Service and Repair/Air Inlet Grille Panel Replacement). 4. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement > Page 11637 Hood Weatherstrip: Service and Repair Hood Rear Outer Seal Replacement Hood Rear Outer Seal Replacement Removal Procedure 1. Open the hood. 2. Pull the rear side hood seal from the pinch-weld flange and motor compartment flange. 3. Remove the rear side hood seal from the vehicle. 4. Using 3M(TM) P/N 8984 Adhesive Remover or equivalent, clean any adhesive from the pinch-weld flange and motor compartment flange surface. Installation Procedure 1. Remove the protective backing paper from the adhesive on the rear side hood seal. 2. Install the rear side hood seal to the pinch-weld flange and motor compartment flange. 3. Press the side rear hood seal onto the pinch-weld flange and motor compartment flange until the adhesive is fully adhered. 4. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations Power Trunk / Liftgate Lock Actuator: Locations Center of the rear compartment lid. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair Trunk / Liftgate Hinge: Service and Repair Rear Compartment Lid Hinge Replacement Removal Procedure 1. Remove the rear compartment lid. Refer to Rear Compartment Lid Replacement (See: Service and Repair/Rear Compartment Lid Replacement). 2. Remove the rear compartment lid struts. Refer to Rear Compartment Lid Strut Replacement (See: Trunk / Liftgate Shock / Support/Service and Repair). 3. Use a grease pencil in order to mark the quarter panel hinge to the quarter panel. 4. Remove the bolts from the rear compartment hinge. 5. Remove the rear compartment hinge from the quarter panel. Installation Procedure 1. Align the rear compartment hinge to the quarter panel. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the rear compartment hinge to rear quarter bolts. Tighten the rear compartment hinge to rear quarter bolts to 25 Nm (18 lb ft). 3. Install the rear compartment lid. Refer to Rear Compartment Lid Replacement (See: Service and Repair/Rear Compartment Lid Replacement). 4. Install the rear compartment lid struts. Refer to Rear Compartment Lid Strut Replacement (See: Trunk / Liftgate Shock / Support/Service and Repair). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair > Page 11645 5. Adjust the rear compartment lid hinge as required. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Locations > Component Locations Trunk / Liftgate Latch: Component Locations Center of the rear compartment lid. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Locations > Component Locations > Page 11650 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Locations > Page 11651 Trunk / Liftgate Latch: Service and Repair Rear Compartment Lid Latch Replacement Removal Procedure 1. Open the rear compartment. 2. Use a grease pencil to mark the location of the rear compartment latch. 3. Disconnect the electrical connectors from the rear compartment latch. 4. Remove the nuts that retain the rear compartment latch. 5. Remove the rear compartment latch from the rear compartment. Installation Procedure 1. Align the rear compartment latch to the marks made on the rear compartment. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the rear compartment latch nuts. Tighten the rear compartment latch nuts to 9 Nm (80 lb in). 3. Connect the electrical connectors to the rear compartment latch. 4. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Locations > Page 11655 Trunk / Liftgate Lock Cylinder: Service and Repair Rear Compartment Lid Lock Cylinder Replacement (Impala) Removal Procedure 1. Remove the rear compartment lid applique. Refer to Rear Compartment Lid Applique Replacement (Impala) (). 2. Drill out the 2 rivets from the rear compartment lock cylinder. 3. Remove the rear compartment lock cylinder and gasket from the rear compartment lid. Installation Procedure 1. Align the lock cylinder shaft to the rear compartment lid latch. 2. Align the rear compartment lock cylinder and gasket to the holes in the rear compartment lid, and press in until fully seated. 3. Install the rear compartment lock cylinder and gasket to the rear compartment lid using 2 rivets. 4. Install the rear compartment lid applique. Refer to Rear Compartment Lid Applique Replacement (Impala) (). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Relay > Component Information > Locations > Rear Compartment Lid Lamp Relay Trunk / Liftgate Relay: Locations Rear Compartment Lid Lamp Relay Inside the top underhood accessory wiring junction block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair Trunk / Liftgate Shock / Support: Service and Repair Rear Compartment Lid Strut Replacement Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Open and support the rear compartment. 2. Using a small flat-bladed tool, lift up the retainer at the bottom and the top of the rear compartment strut. Notice: Apply pressure only at the end of the liftgate/hood assist rod that you are removing or attaching. Do NOT apply pressure to the middle of the rod because damage or bending will result. 3. Remove the rear compartment strut from the ball studs on the hinge. 4. Remove rear compartment strut from the vehicle. Installation Procedure 1. Align the top and bottom of the rear compartment strut with the ball studs on the hinge. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Page 11663 2. Install the rear compartment strut onto the upper ball stud, pressing into place until fully seated. 3. Install the rear compartment strut onto the lower ball stud, pressing into place until fully seated. 4. Close the upper and lower strut retainers. 5. Remove the support and close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations Trunk / Liftgate Solenoid: Locations Center of the rear compartment lid. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations > Page 11667 Rear Compartment Lid Lock Release Actuator Solenoid Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair Trunk / Liftgate Striker: Service and Repair Rear Compartment Lid Latch Striker Replacement Removal Procedure 1. Open the rear compartment. 2. Remove the rear compartment sill plate. Refer to Rear Compartment Sill Trim Plate Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Compartment Sill Trim Plate Replacement). 3. Pull back the rear compartment trim panel. Refer to Rear Compartment Trim Panel Replacement (Two Section) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Compartment Trim Panel Replacement (Two Section)). 4. Remove the rear compartment lid lock striker bolt from inside the rear compartment. 5. Remove the rear licence plate in order to access the access hole. 6. Remove the rear compartment lid lock striker bolts through the access hole. 7. Remove the rear compartment lid lock striker. Installation Procedure 1. Align the rear compartment lid lock striker to the rear compartment body panel. 2. Install the rear compartment lid lock striker bolts to the outside and the inside of the vehicle. Install the outside striker bolts through the access hole. Hand tighten the outside and the inside bolts, allowing for the adjustment of the lock striker for the rear compartment lid. Notice: Refer to Fastener Notice in Cautions and Notices. Important: Because the sealer may squeeze out on the rear compartment lid lock striker bolts, verify the fastener tightening specifications at least twice. 3. Close the rear compartment lid in order to set the adjustment. Tighten the rear compartment lid lock striker outside bolts to 16 Nm (11 lb ft). 4. Open the rear compartment. Tighten the rear compartment lid lock striker inside bolt to 16 Nm (11 lb ft). 5. Install the rear compartment trim. Refer to Rear Compartment Trim Panel Replacement (Two Section) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Compartment Trim Panel Replacement (Two Section)). 6. Install the rear compartment sill plate. Refer to Rear Compartment Sill Trim Plate Replacement (See: Interior Moulding / Trim/Trim Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair > Page 11671 Panel/Service and Repair/Rear Compartment Sill Trim Plate Replacement). 7. Close the rear compartment. 8. Install the rear licence plate. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Component Locations Trunk / Liftgate Switch: Component Locations Rear Compartment Lid Ajar Indicator Switch Center of the rear compartment lid. Rear Compartment Lid Release Switch Locations View Left side of the instrument panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Component Locations > Page 11676 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Page 11677 Rear Compartment Lid Ajar Indicator Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Service and Repair > Rear Compartment Lid Ajar Switch Replacement Trunk / Liftgate Switch: Service and Repair Rear Compartment Lid Ajar Switch Replacement Rear Compartment Lid Ajar Switch Replacement REMOVAL PROCEDURE 1. Open the rear compartment lid. 2. Remove the rear compartment lid latch. Refer to Latch Replacement - Rear Compartment Lid. 3. Remove the rear compartment lid ajar lamp/switch to rear compartment lid latch screw (5). 4. Remove the compartment lid ajar lamp/switch (6) from the rear compartment lid latch (8). INSTALLATION PROCEDURE 1. Position the rear compartment lid ajar lamp/switch (6) to the rear compartment lid latch (8). 2. Install the rear compartment lid ajar lamp/switch to rear compartment lid latch screw (5). Tighten Tighten the rear compartment lid ajar lamp/switch to rear compartment lid latch screw to 5 N.m (44 lb in). 3. Install the rear compartment lid latch. 4. Close the rear compartment lid. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Service and Repair > Rear Compartment Lid Ajar Switch Replacement > Page 11680 Trunk / Liftgate Switch: Service and Repair Rear Compartment Lid Switch Replacement Rear Compartment Lid Switch Replacement REMOVAL PROCEDURE 1. Release the LH instrument panel (IP) insulator tabs from the lower IP trim pad retainers for access. 2. Remove the LH fuse block access cover. 3. Remove the steering column opening filler panel screws. 4. Release the steering column opening filler panel retainers from the IP lower trim panel. Carefully lower the steering column opening filler panel away from the IP lower trim panel. 5. Disconnect the electrical connector from the rear compartment release switch. 6. Remove the rear compartment release switch. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Service and Repair > Rear Compartment Lid Ajar Switch Replacement > Page 11681 1. Install the rear compartment release switch. 2. Connect the electrical connector to the rear compartment release switch. 3. Align the steering column opening filler panel to the instrument panel (IP) lower trim panel. Install the steering column opening filler panel retainers to the IP lower trim panel. 4. Install the steering column opening filler panel screws. Tighten Tighten the steering column opening filler panel screws to 2 N.m (18 lb in). 5. Install the LH IP insulator tabs to the lower IP trim pad retainers. 6. Install the LH fuse block access cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Rear Compartment Lid Weatherstrip Replacement (Impala) Removal Procedure 1. Open the rear compartment. 2. Remove the rear compartment weatherstrip from the pinch-weld flange. Installation Procedure 1. Align the metal joint of the weatherstrip to the center of the rear compartment lid striker. Important: In order to minimize bulging conditions, avoid stretching the weatherstrip around the corners. 2. Install the rear compartment weatherstrip onto the pinch-weld flange, starting at the top center of the lid opening and working toward the bottom center. Use a rubber mallet in order to ensure that the weatherstrip is fully engaged to the pinch-weld flange. 3. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Back Window Glass Moulding / Trim > Component Information > Service and Repair Back Window Glass Moulding / Trim: Service and Repair Rear Window Reveal Molding Replacement Removal Procedure Important: You must remove the rear window in order to replace the rear window reveal molding. The original rear window reveal molding must be replaced with a new service part after removal. 1. Use a flat-bladed tool in order to pry the end of the rear window reveal molding out approximately 75 mm (3 in) from the body. 2. Remove the rear window reveal molding, pulling the rear window reveal molding slowly away from the body. 3. Remove the rear window. Refer to Rear Window Replacement (See: Windows and Glass/Windows/Window Glass/Back Window Glass/Service and Repair). Installation Procedure Important: The new rear window reveal moldings are primed and will adhere to the urethane adhesive. Use a heat lamp, or heat gun if needed, in order to make the rear window reveal molding more pliable. 1. Wipe the rear window area with a clean, dampened cloth using GM Window Cleaner GM P/N 1050427 or isopropyl alcohol in order to clean the surface of the rear window for the installation of the new rear window reveal molding. Allow to air dry. 2. Install the rear window reveal molding to the rear window, starting from the center , hand press the rear window reveal molding into place. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Back Window Glass Moulding / Trim > Component Information > Service and Repair > Page 11689 3. Apply tape if needed, in order to keep the rear window reveal molding on the rear window. 4. Install the rear window. Refer to Rear Window Replacement (See: Windows and Glass/Windows/Window Glass/Back Window Glass/Service and Repair). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Technical Service Bulletins > 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION Body Emblem: Technical Service Bulletins 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION TECHNICAL Bulletin No.: 06-08-111-004B Date: September 25, 2009 Subject: Information on Discoloration, Blistering, Peeling or Erosion of Various Exterior Emblems Including Chevy Bowtie (Bulletin Cancelled) Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being cancelled. Please discard Corporate Bulletin Number 06-08-111-004A (Section 08 - Body & Accessories). This bulletin is being cancelled. The information is no longer applicable. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem/Nameplate Replacement (Rear) Body Emblem: Service and Repair Emblem/Nameplate Replacement (Rear) Emblem/Nameplate Replacement (Impala Rear) Removal Procedure Tools Required J 25070 Heat Gun 1. When replacing or repairing an emblem/nameplate do the following: 1. Use tape to protect the mounting surface during removal. 2. Use tape for alignment marks for installation of the emblem/nameplate. 2. To remove an emblem/nameplate, heat the emblem/nameplate using a J 25070 Apply heat using a circular motion for about 30 seconds. Notice: Use a plastic, flat-bladed tool to prevent paint damage when removing an emblem/name plate. 3. Use a plastic, flat-bladed tool to lift or remove the emblem/nameplate from the panel surface. Important: If tape is still intact on the molding or panel, do not remove the tape. Clean the tape and the mating surface with adhesive cleaner. Wipe the tape and the mating surface with a clean, lint free cloth. If the tape is damaged, continue with the replacement procedure. 4. Apply the adhesive foam tape to the back of the emblem/nameplate and press the emblem/nameplate in place. 5. When replacing, remove all adhesive as follows: * For body panels use a 3M(TM) Scotch Brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. * For plastic panels use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a (50/50 mixture) by volume of isopropyl alcohol and water in order to remove the adhesive. Installation Procedure Important: Apply the emblem/nameplate in an environment that is free from dust or other dirt that could come into contact with the sticky backing. Foreign material may cause improper adhesion. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem/Nameplate Replacement (Rear) > Page 11696 1. Clean the area where the emblem/nameplate will be installed. Use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a (50/50 mixture) by volume of isopropyl alcohol and water in order to clean the area. 2. Dry the area thoroughly. 3. If the location of the emblem/nameplate has not been marked, apply tape and mark the location as shown. 4. Heat the mounting surface to approximately 27-41°C (80-105°F). 5. Ensure that the temperature of the emblem/name plate is approximately 29-32°C (85-90°F). 6. Remove the protective liner from the back of the emblem/name plate. 7. Position the emblem/name plate to the location marks and press the emblem/name plate to the mounting surface. 8. Apply equal pressure along the emblem/name plate in order to uniformly bond the item to the mounting surface. 9. Remove the protective tape from the mounting surface. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem/Nameplate Replacement (Rear) > Page 11697 Body Emblem: Service and Repair Emblem/Nameplate Replacement (Quarter Panel) Emblem/Nameplate Replacement (Impala Quarter Panel) Removal Procedure Tools Required J 25070 Heat Gun 1. When replacing or repairing an emblem/nameplate do the following: 1. Use tape to protect the mounting surface during removal. 2. Use tape for alignment marks for installation of the emblem/nameplate. 2. To remove an emblem/nameplate, heat the emblem/nameplate using a J 25070 Apply heat using a circular motion for about 30 seconds. Notice: Use a plastic, flat-bladed tool to prevent paint damage when removing an emblem/name plate. 3. Use a plastic, flat-bladed tool to lift or remove the emblem/nameplate from the panel surface. Important: If tape is still intact on the molding or panel, do not remove the tape. Clean the tape and the mating surface with adhesive cleaner. Wipe the tape and the mating surface with a clean, lint free cloth. If the tape is damaged, continue with the replacement procedure. 4. Apply the adhesive foam tape to the back of the emblem/nameplate and press the emblem/nameplate in place. 5. When replacing, remove all adhesive as follows: * For body panels use a 3M(TM) Scotch Brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. * For plastic panels use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a (50/50 mixture) by volume of isopropyl alcohol and water in order to remove the adhesive. Installation Procedure Important: Apply the emblem/nameplate in an environment that is free from dust or other dirt that could come into contact with the sticky backing. Foreign material may cause improper adhesion. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem/Nameplate Replacement (Rear) > Page 11698 1. Clean the area where the emblem/nameplate will be installed. Use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a (50/50 mixture) by volume of isopropyl alcohol and water in order to clean the area. 2. Dry the area thoroughly. 3. If the location of the emblem/nameplate has not been marked, apply tape and mark the location as shown. 4. Heat the mounting surface to approximately 27-41°C (80-105°F). 5. Ensure that the temperature of the emblem/name plate is approximately 29-32°C (85-90°F). 6. Remove the protective liner from the back of the emblem/name plate. 7. Position the emblem/name plate to the location marks and press the emblem/name plate to the mounting surface. 8. Apply equal pressure along the emblem/name plate in order to uniformly bond the item to the mounting surface. 9. Remove the protective tape from the mounting surface. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem/Nameplate Replacement (Rear) > Page 11699 Body Emblem: Service and Repair Emblem/Nameplate Replacement (Door) Emblem/Nameplate Replacement (Impala Door) Removal Procedure Tools Required J 25070 Heat Gun 1. When replacing or repairing an emblem/nameplate do the following: 1. Use tape to protect the mounting surface during removal. 2. Use tape for alignment marks for installation of the emblem/nameplate. 2. To remove an emblem/nameplate, heat the emblem/nameplate using a J 25070 Apply heat using a circular motion for about 30 seconds. Notice: Use a plastic, flat-bladed tool to prevent paint damage when removing an emblem/name plate. 3. Use a plastic, flat-bladed tool to lift or remove the emblem/nameplate from the panel surface. Important: If tape is still intact on the molding or panel, do not remove the tape. Clean the tape and the mating surface with adhesive cleaner. Wipe the tape and the mating surface with a clean, lint free cloth. If the tape is damaged, continue with the replacement procedure. 4. Apply the adhesive foam tape to the back of the emblem/nameplate and press the emblem/nameplate in place. 5. When replacing, remove all adhesive as follows: * For body panels use a 3M(TM) Scotch Brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. * For plastic panels use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a (50/50 mixture) by volume of isopropyl alcohol and water in order to remove the adhesive. Installation Procedure Important: Apply the emblem/nameplate in an environment that is free from dust or other dirt that could come into contact with the sticky backing. Foreign material may cause improper adhesion. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem/Nameplate Replacement (Rear) > Page 11700 1. Clean the area where the emblem/nameplate will be installed. Use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a (50/50 mixture) by volume of isopropyl alcohol and water in order to clean the area. 2. Dry the area thoroughly. 3. If the location of the emblem/nameplate has not been marked, apply tape and mark the location as shown. 4. Heat the mounting surface to approximately 27-41°C (80-105°F). 5. Ensure that the temperature of the emblem/name plate is approximately 29-32°C (85-90°F). 6. Remove the protective liner from the back of the emblem/name plate. 7. Position the emblem/name plate to the location marks and press the emblem/name plate to the mounting surface. 8. Apply equal pressure along the emblem/name plate in order to uniformly bond the item to the mounting surface. 9. Remove the protective tape from the mounting surface. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem/Nameplate Replacement (Rear) > Page 11701 Body Emblem: Service and Repair Emblem/Nameplate Replacement (Rear Applique) Emblem/Nameplate Replacement (Impala Rear Applique) Removal Procedure Tools Required J 25070 Heat Gun 1. When replacing or repairing an emblem/nameplate do the following: 1. Use tape to protect the mounting surface during removal. 2. Use tape for alignment marks for installation of the emblem/nameplate. 2. To remove an emblem/nameplate, heat the emblem/nameplate using a J 25070 Apply heat using a circular motion for about 30 seconds. Notice: Use a plastic, flat-bladed tool to prevent paint damage when removing an emblem/name plate. 3. Use a plastic, flat-bladed tool to lift or remove the emblem/nameplate from the panel surface. Important: If tape is still intact on the molding or panel, do not remove the tape. Clean the tape and the mating surface with adhesive cleaner. Wipe the tape and the mating surface with a clean, lint free cloth. If the tape is damaged, continue with the replacement procedure. 4. Apply the adhesive foam tape to the back of the emblem/nameplate and press the emblem/nameplate in place. 5. When replacing, remove all adhesive as follows: * For body panels use a 3M(TM) Scotch Brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. * For plastic panels use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a (50/50 mixture) by volume of isopropyl alcohol and water in order to remove the adhesive. Installation Procedure Important: Apply the emblem/nameplate in an environment that is free from dust or other dirt that could come into contact with the sticky backing. Foreign material may cause improper adhesion. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem/Nameplate Replacement (Rear) > Page 11702 1. Clean the area where the emblem/nameplate will be installed. Use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a (50/50 mixture) by volume of isopropyl alcohol and water in order to clean the area. 2. Dry the area thoroughly. 3. If the location of the emblem/nameplate has not been marked, apply tape and mark the location as shown. 4. Heat the mounting surface to approximately 27-41°C (80-105°F). 5. Ensure that the temperature of the emblem/name plate is approximately 29-32°C (85-90°F). 6. Remove the protective liner from the back of the emblem/name plate. 7. Position the emblem/name plate to the location marks and press the emblem/name plate to the mounting surface. 8. Apply equal pressure along the emblem/name plate in order to uniformly bond the item to the mounting surface. 9. Remove the protective tape from the mounting surface. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem/Nameplate Replacement (Rear) > Page 11703 Body Emblem: Service and Repair Front Bumper Fascia Emblem/Nameplate Replacement (Coupe) Front Bumper Fascia Emblem/Nameplate Replacement (Coupe) Removal Procedure Tools Required J 25070 Heat Gun 1. When replacing or repairing an emblem/nameplate do the following: 1. Use tape to protect the mounting surface during removal. 2. Use tape for alignment marks for installation of the emblem/nameplate. 2. To remove an emblem/nameplate, heat the emblem/nameplate using a J 25070 Apply heat using a circular motion for about 30 seconds. Notice: Use a plastic, flat-bladed tool to prevent paint damage when removing an emblem/name plate. 3. Use a plastic, flat-bladed tool to lift or remove the emblem/nameplate from the panel surface. Important: If tape is still intact on the molding or panel, do not remove the tape. Clean the tape and the mating surface with adhesive cleaner. Wipe the tape and the mating surface with a clean, lint free cloth. If the tape is damaged, continue with the replacement procedure. 4. Apply the adhesive foam tape to the back of the emblem/nameplate and press the emblem/nameplate in place. 5. When replacing, remove all adhesive as follows: * For body panels use a 3M(TM) Scotch Brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. * For plastic panels use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a (50/50 mixture) by volume of isopropyl alcohol and water in order to remove the adhesive. Installation Procedure Important: Apply the emblem/nameplate in an environment that is free from dust or other dirt that could come into contact with the sticky backing. Foreign material may cause improper adhesion. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem/Nameplate Replacement (Rear) > Page 11704 1. Clean the area where the emblem/nameplate will be installed. Use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a (50/50 mixture) by volume of isopropyl alcohol and water in order to clean the area. 2. Dry the area thoroughly. 3. If the location of the emblem/nameplate has not been marked, apply tape and mark the location as shown. 4. Heat the mounting surface to approximately 27-41°C (80-105°F). 5. Ensure that the temperature of the emblem/name plate is approximately 29-32°C (85-90°F). 6. Remove the protective liner from the back of the emblem/name plate. 7. Position the emblem/name plate to the location marks and press the emblem/name plate to the mounting surface. 8. Apply equal pressure along the emblem/name plate in order to uniformly bond the item to the mounting surface. 9. Remove the protective tape from the mounting surface. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Plenum Water Deflector Replacement Cowl Moulding / Trim: Service and Repair Plenum Water Deflector Replacement Plenum Water Deflector Replacement Removal Procedure 1. Open the hood. 2. Remove the right side of the air inlet grille. Refer to Air Inlet Grille Panel Replacement (See: Air Inlet Grille Panel Replacement). 3. Remove the plenum chamber deflector from the pinch-weld flange, by lifting up and out. Installation Procedure 1. Install the plenum chamber deflector to the pinch-weld flange. 2. Install the right side of the air inlet grille. Refer to Air Inlet Grille Panel Replacement (See: Air Inlet Grille Panel Replacement). 3. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Plenum Water Deflector Replacement > Page 11709 Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Air Inlet Grille Panel Replacement Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the hood. 2. Remove the wiper arms. Refer to Windshield Wiper Arm Replacement in Wipers/Washer Systems. 3. Disconnect the windshield wiper washer hose from the air inlet grille. 4. Use the J 38778 to remove the push-in retainers from the air inlet grille. 5. Remove the air inlet grille from the vehicle. Installation Procedure 1. Install the air inlet grille to the vehicle. 2. Install the push-in retainers to the air inlet grille. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Plenum Water Deflector Replacement > Page 11710 3. Install the windshield wiper washer hose to the air inlet grille. 4. Install the wiper arms. Refer to Windshield Wiper Arm Replacement in Wipers/Washer Systems. 5. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Lower Side Moulding / Trim: > 99-08-111-02 > Sep > 99 > Rocker Moulding and Body - Gap Between Center Lower Side Moulding / Trim: Customer Interest Rocker Moulding and Body - Gap Between Center File In Section: 08 - Body and Accessories Bulletin No.: 99-08-111-002 Date: September, 1999 Subject: Gap Between Center of Rocker Molding and Retaining Clip or Between Center of Rocker Molding and Body (Replace Center Retaining Clip) Models: 2000 Chevrolet Impala Condition Some customers may comment that there is a gap between the center of the rocker molding (2) and the retaining clip (1) or between the center of the rocker molding and the body at the base of the "B" pillar, just forward of the rear side door (3). This condition may exist on either the driver or passenger side of the vehicle. Cause The center retaining clip (1) will not engage completely into the body sheet metal. Correction Install a new center retaining clip that has a smaller head and a different shaped fastener, using the following procedure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Lower Side Moulding / Trim: > 99-08-111-02 > Sep > 99 > Rocker Moulding and Body - Gap Between Center > Page 11719 Important: This new center retaining clip is different than the other seven retaining clips that attach the rocker molding and should only be used at the center location. 1. Open the front door. Important: To protect the paint surface when removing the original center retaining clip in the next step, apply masking tape as necessary to the rocker molding. 2. Using a sharp utility knife, cut the head off of the original center retaining clip (1) by inserting the blade down through the gap between the head of the retaining clip and the rocker molding (2). If necessary, hold the rocker molding against the vehicle body to improve access. Discard the head of the clip. 3. Using a small flat bladed tool, push the remaining stud portion of the plastic clip into the body. The stud portion of the original plastic clip will remain in the rocker panel and will NOT cause a rattle. 4. Align the hole in the rocker molding with the hole in the vehicle body and push the new retaining clip in until the molding is flush with the body and the clip is fully seated. 5. Remove the protective masking tape. Parts Information Parts are currently available from GMSPO Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time B9702 Rocker Molding Retaining 0.2 hr Clip - Replace one or both Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lower Side Moulding / Trim: > 99-08-111-02 > Sep > 99 > Rocker Moulding and Body - Gap Between Center Lower Side Moulding / Trim: All Technical Service Bulletins Rocker Moulding and Body - Gap Between Center File In Section: 08 - Body and Accessories Bulletin No.: 99-08-111-002 Date: September, 1999 Subject: Gap Between Center of Rocker Molding and Retaining Clip or Between Center of Rocker Molding and Body (Replace Center Retaining Clip) Models: 2000 Chevrolet Impala Condition Some customers may comment that there is a gap between the center of the rocker molding (2) and the retaining clip (1) or between the center of the rocker molding and the body at the base of the "B" pillar, just forward of the rear side door (3). This condition may exist on either the driver or passenger side of the vehicle. Cause The center retaining clip (1) will not engage completely into the body sheet metal. Correction Install a new center retaining clip that has a smaller head and a different shaped fastener, using the following procedure. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lower Side Moulding / Trim: > 99-08-111-02 > Sep > 99 > Rocker Moulding and Body - Gap Between Center > Page 11725 Important: This new center retaining clip is different than the other seven retaining clips that attach the rocker molding and should only be used at the center location. 1. Open the front door. Important: To protect the paint surface when removing the original center retaining clip in the next step, apply masking tape as necessary to the rocker molding. 2. Using a sharp utility knife, cut the head off of the original center retaining clip (1) by inserting the blade down through the gap between the head of the retaining clip and the rocker molding (2). If necessary, hold the rocker molding against the vehicle body to improve access. Discard the head of the clip. 3. Using a small flat bladed tool, push the remaining stud portion of the plastic clip into the body. The stud portion of the original plastic clip will remain in the rocker panel and will NOT cause a rattle. 4. Align the hole in the rocker molding with the hole in the vehicle body and push the new retaining clip in until the molding is flush with the body and the clip is fully seated. 5. Remove the protective masking tape. Parts Information Parts are currently available from GMSPO Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time B9702 Rocker Molding Retaining 0.2 hr Clip - Replace one or both Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Technical Service Bulletins > Page 11726 Lower Side Moulding / Trim: Service and Repair Body Side Molding Replacement Adhesive Body Side Moldings End Loose Important: The body side moldings are attached to the body panels with adhesive tape. To insure a good replacement of new or old moldings emblems and name plates, the panel surface should be warm 21-32°C (70-90°F), clean, and free of any wax or oily film. Methods are listed to attach loose molding ends, completely removed moldings and replacement moldings emblem and name plates. 1. Wash the affected area with soap and water and wipe dry. Wipe the panel and the adhesive side of the molding with a clean rag using Varnish Makers and Painters (VM&P;) Naphtha. 2. If needed apply a length of masking tape as a molding guide. A straightedge may also be used. 3. Apply the adhesive to the back of the molding and press in place. If the adhesive GM P/N 1052621 or equivalent is used apply the constant pressure to the molding for 30 seconds or until a firm bond has been made. Adhesive Body Side Molding Completely Removed 1. Remove all adhesive from the body panel and the back of the molding using 3M(TM) scotch brite molding adhesive remover disk, 3M(TM) P/N 07501 or equivalent. 2. Wash the affected panel area with soap and water and wipe dry. 3. Remove all traces of adhesive from the body panel and the back of the molding using Varnish Makers and Painters (VM&P;) Naphtha. 4. Mark the proper position of the molding with a length of masking tape. Use adjacent moldings as a guide. 5. Warm the body panel with the heat lamp or the heat gun to a minimum of 21°C (70°F). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Technical Service Bulletins > Page 11727 6. Apply a piece of double-coated foam tape, 3M(TM) P/N 06382 Gray or equivalent to the molding. 7. Align the molding to the tape guideline on the body panel. 8. Peel the backing from the end of the molding. 9. Press firmly into place while continuing to remove the backing. 10. Hand roll the molding to the body in order to ensure the proper adhesion. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair Windshield Moulding / Trim: Service and Repair Windshield Reveal Molding Replacement Removal Procedure Important: * Be sure to prefit the windshield reveal molding to the windshield then as an assembly on the body prior to actual installation. * When replacing the windshield, the original windshield reveal molding cannot be reused and must be replaced with a new molding. * The new windshield reveal moldings are primed and will adhere to the urethane adhesive. * A heat lamp may be used to make the windshield reveal molding more pliable. * The windshield reveal molding cannot be replaced without removing the windshield. 1. Remove the windshield using a flat-bladed tool, and carefully pry the end of the windshield reveal molding out about 75 mm (3 in). 2. Grasp the windshield reveal molding by hand and slowly pull the windshield reveal molding away from the body. 3. Remove the windshield. Refer to Windshield Replacement (See: Windows and Glass/Windshield/Service and Repair). Installation Procedure 1. Start from center and hand press the windshield reveal molding into place. Tape can be applied to keep windshield reveal molding flush with windshield. 2. Prefit the windshield reveal molding and the windshield then as an assembly on the body prior to actual installation. 3. Install the windshield. Refer to Windshield Replacement (See: Windows and Glass/Windshield/Service and Repair). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair Front Fender Liner Replacement Removal Procedure 1. Drill out the plastic rivets from the front fascia extension corner to front fender liner, if equipped. 2. Remove the screws from the front fender liner at the front bumper fascia. 3. Remove the nut from the stud at the rear of the front fender liner. 4. Remove the bolt from the front tab of the front fender liner at the lower engine compartment side rail. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Page 11736 5. Remove the screws from the front fender liner. 6. Drill out the plastic rivet from the front rocker panel to front fender liner, if equipped. 7. Remove the front fender liner. Installation Procedure 1. Position the fender liner to the fender, over the stud and behind the rocker molding. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the nut to the stud at the rear of the front fender liner. Tighten the front fender liner stud nut to 4 Nm (35 lb in). 3. Install the screws to the front fender liner at the front bumper fascia. Tighten the front fender liner to front bumper fascia screws to 2 Nm (18 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Page 11737 4. Install the screws to the front fender liner. Tighten the front fender liner screws to 2 Nm (18 lb in). 5. Using a new plastic rivet, install the plastic rivet to the rocker panel and front fender liner, if equipped. 6. Install the bolt to the front tab of the front fender liner at the lower engine compartment side rail. Tighten the front fender liner to rear of fender bolt to 7 Nm (61 lb in). 7. Using new plastic rivets, install the plastic rivets to the front fascia extension corner and front fender liner. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Firewall > Component Information > Service and Repair Firewall: Service and Repair Engine Dash Mat Replacement - Side The engine side dash mat is composed of a thermoplastic rubber. The material is flexible, so the most desirable way to service the dash mat or to make any repair behind it is locally pull away or remove the dash mat. In many cases, the dash mat can be pulled away in one area so that a repair can be made behind it. However, there may be an instance where it is necessary to cut the dash mat in order to make a repair. Although it is not desirable to cut the dash mat, if it becomes necessary, the recommended procedure to repair the cut is as follows: 1. Prepare the surface surrounding the cut by lightly sanding the area. 2. Apply contact cement between the cut surface and the surrounding area. 3. Allow the cement to cure before stressing the repaired area. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair Cross-Member: Service and Repair Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the exhaust pipe. Refer to Exhaust Pipe Replacement (Single Exhaust) or Exhaust Pipe Replacement (Dual Exhaust) in Engine Exhaust. 3. Disconnect the brake lines from the rear suspension support. Refer to Hydraulic Brakes. 4. Disconnect the parking brake cables from the suspension support. Refer to Park Brake Cable Replacement (Front) or Park Brake Cable Replacement (Left/right rear) in Parking Brakes. 5. Disconnect the stabilizer shaft from the rear stabilizer shaft links. 6. Disconnect the stabilizer shaft from the rear suspension support. Important: Support the rear suspension support with jack stands before removing the mounting bolts. 7. Remove the rear suspension support mounting bolts. 8. Disconnect the rear wheel spindle rods from the knuckle. 9. Lower the rear suspension support in order to gain access to the rear wheel spindle rod bolts. 10. Disconnect the rear wheel spindle rods from the rear suspension support. 11. Remove the ABS wiring harness and retainers from the rear suspension support. Remove the rear suspension support. Installation Procedure 1. Position the rear suspension support in place. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the rear wheel spindle rod-to-rear suspension support bolts and nuts. Tighten the rear wheel spindle rod-to-rear suspension support nuts to 140 Nm (103 ft. lbs.). 3. Install the rear suspension support mounting bolts. Tighten the rear suspension support mounting bolts to 105 Nm (77 ft. lbs.). 4. Position the rear wheel spindle rod to the knuckle. Install the retaining bolts and nuts to the knuckle. Tighten the spindle rod-to-knuckle retaining nut to 150 Nm(110 ft. lbs.). 5. Connect the brake lines to the rear suspension support. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Page 11745 6. Install the parking brake cables and the tensioner. Refer to Park Brake Cable Replacement (Front) or Park Brake Cable Replacement (Left/right rear) in Parking Brakes. 7. Install the stabilizer shaft brackets to the rear suspension support. 8. Install the stabilizer shaft bracket bolts to the rear suspension support. Important: Insert the bracket bolts facing rearward. Do not tighten the bolts at this time. 9. Install the stabilizer shaft-to-stabilizer shaft link nuts. Tighten the shaft link nuts to 35 Nm (26 ft. lbs.). 10. Connect the stabilizer shaft to the rear suspension support. 11. Install the stabilizer shaft insulator bracket bolt. Tighten the stabilizer shaft insulator bracket bolts to 48 Nm (35 ft. lbs.). 12. Lower the vehicle. 13. Adjust the rear wheel alignment. Refer to Wheel Alignment Specifications (Front) or Wheel Alignment Specifications (Rear) in Wheel Alignment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Strut Tower Brace > Component Information > Service and Repair Strut Tower Brace: Service and Repair Cross Vehicle Brace Replacement Removal Procedure 1. Open the hood. 2. Remove the nuts from the cross vehicle brace. 3. Remove the cross vehicle brace from the vehicle. Important: Be careful, the stud plates may fall out and possibly get caught under the vehicle during the removal. 4. Remove the stud plates push on nuts from the studs. 5. Remove the stud plates from the vehicle. Installation Procedure Important: The stud plates will require an assistant to hold the stud plates during the installation of the push on nuts. 1. Install the stud plates to the vehicle. 2. Install the stud plates push on nuts to the studs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Strut Tower Brace > Component Information > Service and Repair > Page 11749 3. Install the cross vehicle brace to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the nuts to the cross vehicle brace. Tighten the cross vehicle brace nuts to 18 Nm (13 lb ft). 5. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair Front Subframe: Service and Repair Frame Removal Tools Required J 39580 Universal Engine Support Table Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the air cleaner assembly. 3. Install the engine support Fixture. 4. Raise and support the vehicle. 5. Remove the front tires and wheels. 6. Remove the steering gear mounting bolts. 7. Use a strap in order to secure the power steering gear. 8. Remove the engine mount to frame nuts. 9. Remove the transaxle mount to frame nuts. 10. Remove the power steering cooler pipe from the frame. 11. Use utility wire to secure the power steering cooler. 12. Disconnect the front wheel speed sensor connectors (1). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Page 11754 13. Remove the front wheel speed harness retainers from the frame and the lower control arms (2). 14. Separate both of the lower ball joints from the steering knuckle. 15. Lower the vehicle until the frame contacts the J 39580. 16. Remove and DISCARD all frame-to-body bolts. 17. Raise the vehicle in order to separate the frame from the body. 18. If you are replacing the frame, remove the following components: ^ The spacers, the upper insulators, the lower insulators, and the retainers. ^ Both of the lower control arms. ^ The stabilizer shaft. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Page 11755 1. If previously removed, install the following components: Important: Ensure that the insulators are completely seated against the frame. ^ The spacers, the upper insulators, the lower insulators, and the retainers. ^ Both of the lower control arms. ^ The stabilizer shaft. 2. Position the engine support table with the frame under the vehicle. 3. Lower the vehicle to the frame. 4. Align the frame to the body by inserting two 19 X 203 mm (0.74 X 8.0 in) pins in the alignment holes on the right side of the frame. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 5. Install the NEW frame-to-body bolts. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Page 11756 Tighten Tighten the bolts to 180 Nm (133 lb ft). 6. Install the engine mount nuts. 7. Install the transaxle mount nuts. 8. Connect the lower ball joints to the steering knuckle. 9. Install the steering gear mounting bolts. 10. Install the power steering cooler pipe to the frame. 11. Connect the front wheel speed sensor connectors (1). 12. Install the front wheel speed harness retainers from the frame and the lower control arms (2). 13. Remove the universal support table. 14. Install the front tires and wheels. 15. Lower the vehicle. 16. Remove the engine support fixture. 17. Connect the negative battery cable. 18. Install the air cleaner assembly. 19. Inspect the front wheel alignment and adjust if needed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > Customer Interest for Front Subframe Mount: > 00-08-61-003 > Oct > 00 > Frame - Clunk/Pop Noise Front Subframe Mount: Customer Interest Frame - Clunk/Pop Noise File In Section: 08 - Body and Accessories Bulletin No.: 00-08-61-003 Date: October, 2000 TECHNICAL Subject: Clunk/Pop Noise From Front Of Vehicle (Shim Rear Frame/Cradle Mounts) Models: 2000 Chevrolet Impala, Monte Carlo Condition Some customers may comment about a clunk or pop type noise coming from the front of the vehicle. This condition can be duplicated and is most apparent during either a heavy acceleration from a stop or moderate to heavy brake apply at low speeds. Cause This condition may be caused by fore/aft movement of the two rear frame/cradle mounts in the frame/cradle assembly. Correction Install shim material contained in service kit, P/N 10306243, between the rear mounts and the frame/cradle assembly, using the following procedure: 1. Raise vehicle and support the rear of the frame/cradle assembly. 2. Remove the two rear frame/cradle mount bolts and the lower retainers. 3. Lower the rear of the frame/cradle assembly 50 mm (2 in). 4. Remove the two rear mount upper insulators. 5. Remove the two rear mount lower insulators. 6. Cut shim material contained in service kit, P/N 10306243, into four equal pieces 25 mm X 62 mm (1 in X 2-1/2 in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > Customer Interest for Front Subframe Mount: > 00-08-61-003 > Oct > 00 > Frame - Clunk/Pop Noise > Page 11765 7. With the shiny surface of the shim material facing away from the mount lower insulators, position a piece of the shim material (1) on both the fore and aft surfaces of the insulators as shown in the figure. 8. While holding the shim material (1) in position, install lower insulators into the frame/cradle assembly. 9. Generously lubricate the upper insulators with rubber lubricate, P/N 12345884 and install. 10. Raise the rear of the frame/cradle assembly up to the vehicle underbody. 11. Install mount lower insulator retainers and hand start frame/cradle mount bolts. Tighten Tighten the frame/cradle mount bolts to 160 Nm (118 lb ft). 12. Remove the support and lower the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > Customer Interest for Front Subframe Mount: > 00-08-61-003 > Oct > 00 > Frame - Clunk/Pop Noise > Page 11766 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > 00-08-61-003 > Oct > 00 > Frame - Clunk/Pop Noise Front Subframe Mount: All Technical Service Bulletins Frame - Clunk/Pop Noise File In Section: 08 - Body and Accessories Bulletin No.: 00-08-61-003 Date: October, 2000 TECHNICAL Subject: Clunk/Pop Noise From Front Of Vehicle (Shim Rear Frame/Cradle Mounts) Models: 2000 Chevrolet Impala, Monte Carlo Condition Some customers may comment about a clunk or pop type noise coming from the front of the vehicle. This condition can be duplicated and is most apparent during either a heavy acceleration from a stop or moderate to heavy brake apply at low speeds. Cause This condition may be caused by fore/aft movement of the two rear frame/cradle mounts in the frame/cradle assembly. Correction Install shim material contained in service kit, P/N 10306243, between the rear mounts and the frame/cradle assembly, using the following procedure: 1. Raise vehicle and support the rear of the frame/cradle assembly. 2. Remove the two rear frame/cradle mount bolts and the lower retainers. 3. Lower the rear of the frame/cradle assembly 50 mm (2 in). 4. Remove the two rear mount upper insulators. 5. Remove the two rear mount lower insulators. 6. Cut shim material contained in service kit, P/N 10306243, into four equal pieces 25 mm X 62 mm (1 in X 2-1/2 in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > 00-08-61-003 > Oct > 00 > Frame - Clunk/Pop Noise > Page 11772 7. With the shiny surface of the shim material facing away from the mount lower insulators, position a piece of the shim material (1) on both the fore and aft surfaces of the insulators as shown in the figure. 8. While holding the shim material (1) in position, install lower insulators into the frame/cradle assembly. 9. Generously lubricate the upper insulators with rubber lubricate, P/N 12345884 and install. 10. Raise the rear of the frame/cradle assembly up to the vehicle underbody. 11. Install mount lower insulator retainers and hand start frame/cradle mount bolts. Tighten Tighten the frame/cradle mount bolts to 160 Nm (118 lb ft). 12. Remove the support and lower the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > 00-08-61-003 > Oct > 00 > Frame - Clunk/Pop Noise > Page 11773 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 11774 Front Subframe Mount: By Symptom Technical Service Bulletin # 00-08-61-003 Date: 001001 Frame - Clunk/Pop Noise File In Section: 08 - Body and Accessories Bulletin No.: 00-08-61-003 Date: October, 2000 TECHNICAL Subject: Clunk/Pop Noise From Front Of Vehicle (Shim Rear Frame/Cradle Mounts) Models: 2000 Chevrolet Impala, Monte Carlo Condition Some customers may comment about a clunk or pop type noise coming from the front of the vehicle. This condition can be duplicated and is most apparent during either a heavy acceleration from a stop or moderate to heavy brake apply at low speeds. Cause This condition may be caused by fore/aft movement of the two rear frame/cradle mounts in the frame/cradle assembly. Correction Install shim material contained in service kit, P/N 10306243, between the rear mounts and the frame/cradle assembly, using the following procedure: 1. Raise vehicle and support the rear of the frame/cradle assembly. 2. Remove the two rear frame/cradle mount bolts and the lower retainers. 3. Lower the rear of the frame/cradle assembly 50 mm (2 in). 4. Remove the two rear mount upper insulators. 5. Remove the two rear mount lower insulators. 6. Cut shim material contained in service kit, P/N 10306243, into four equal pieces 25 mm X 62 mm (1 in X 2-1/2 in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 11775 7. With the shiny surface of the shim material facing away from the mount lower insulators, position a piece of the shim material (1) on both the fore and aft surfaces of the insulators as shown in the figure. 8. While holding the shim material (1) in position, install lower insulators into the frame/cradle assembly. 9. Generously lubricate the upper insulators with rubber lubricate, P/N 12345884 and install. 10. Raise the rear of the frame/cradle assembly up to the vehicle underbody. 11. Install mount lower insulator retainers and hand start frame/cradle mount bolts. Tighten Tighten the frame/cradle mount bolts to 160 Nm (118 lb ft). 12. Remove the support and lower the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 11776 Disclaimer Technical Service Bulletin # 00-08-61-003 Date: 001001 Frame - Clunk/Pop Noise File In Section: 08 - Body and Accessories Bulletin No.: 00-08-61-003 Date: October, 2000 TECHNICAL Subject: Clunk/Pop Noise From Front Of Vehicle (Shim Rear Frame/Cradle Mounts) Models: 2000 Chevrolet Impala, Monte Carlo Condition Some customers may comment about a clunk or pop type noise coming from the front of the vehicle. This condition can be duplicated and is most apparent during either a heavy acceleration from a stop or moderate to heavy brake apply at low speeds. Cause This condition may be caused by fore/aft movement of the two rear frame/cradle mounts in the frame/cradle assembly. Correction Install shim material contained in service kit, P/N 10306243, between the rear mounts and the frame/cradle assembly, using the following procedure: 1. Raise vehicle and support the rear of the frame/cradle assembly. 2. Remove the two rear frame/cradle mount bolts and the lower retainers. 3. Lower the rear of the frame/cradle assembly 50 mm (2 in). 4. Remove the two rear mount upper insulators. 5. Remove the two rear mount lower insulators. 6. Cut shim material contained in service kit, P/N 10306243, into four equal pieces 25 mm X 62 mm (1 in X 2-1/2 in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 11777 7. With the shiny surface of the shim material facing away from the mount lower insulators, position a piece of the shim material (1) on both the fore and aft surfaces of the insulators as shown in the figure. 8. While holding the shim material (1) in position, install lower insulators into the frame/cradle assembly. 9. Generously lubricate the upper insulators with rubber lubricate, P/N 12345884 and install. 10. Raise the rear of the frame/cradle assembly up to the vehicle underbody. 11. Install mount lower insulator retainers and hand start frame/cradle mount bolts. Tighten Tighten the frame/cradle mount bolts to 160 Nm (118 lb ft). 12. Remove the support and lower the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use table. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 11778 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Service and Repair > Drivetrain and Front Suspension Frame Front Insulator Replacement Front Subframe Mount: Service and Repair Drivetrain and Front Suspension Frame Front Insulator Replacement Drivetrain and Front Suspension Frame Front Insulator Replacement Tools Required J 45296 Frame Insulator Remover/Installer Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Disconnect the steering intermediate shaft. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column. 3. Disconnect the fog lamp electrical connectors from the fog lamps. 4. Install a jackstand under the center of the frame, between the front frame insulators. 5. Remove the front frame bolts and retainers. 6. Lower the front of the frame. 7. Remove the frame front upper insulators. 8. Install the J 45296 to the front frame insulator you are removing. 9. Using J 45296 , remove the front frame insulator from the frame. Installation Procedure 1. Clean the front frame insulator opening. 2. Apply a thin coat of rubber lubricant GM P/N 1051717 or equivalent to the inside of the front frame insulator opening. 3. Apply a thin coat of rubber lubricant GM P/N 1051717 or equivalent to the front frame insulator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Service and Repair > Drivetrain and Front Suspension Frame Front Insulator Replacement > Page 11781 4. Align the front frame insulator to the front frame opening with the front frame alignment tabs facing to the front. 5. Using J 45296 , install the front frame insulator to the front frame. 6. Install the frame front upper insulators. 7. Raise the front of the frame. Notice: Refer to Fastener Notice in Cautions and Notices. 8. Install the front frame bolts and retainers. Tighten the front frame bolts to 180 Nm (133 lb ft). 9. Remove the jackstand. 10. Connect the fog lamp electrical connectors to the fog lamps. 11. Connect the steering intermediate shaft. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column. 12. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Service and Repair > Drivetrain and Front Suspension Frame Front Insulator Replacement > Page 11782 Front Subframe Mount: Service and Repair Drivetrain and Front Suspension Frame Rear Insulator Replacement Drivetrain and Front Suspension Frame Rear Insulator Replacement Removal Procedure Important: In order to remove any frame insulator, loosen the adjacent frame insulators to permit the frame to separate from the body. Do not break the fan shroud or damage the frame attachments, such as steering hoses and brake pipes during the replacement of body mounts. When installing a body mount, ensure the lower insulator is seated into the frame. The lower insulator should not be loose. The spacer and the corresponding upper insulator is pressed into the lower insulator thus squeezing the frame. The bolt is then inserted through the mount, capturing the lower retainer. The body mount components prevent contact of the frame to the body. Do not over tighten the body mount. Over tightening may collapse a spacer or strip a bolt. When the frame insulator bolts are removed, always discard the bolts and replace with new bolts. When clamping by the mount, ensure the surfaces are clean and dry. If the frame insulator bolt does not screw in smoothly, run a tap through the frame crossmember nut in the body in order to remove foreign material. Ensure the tap does not punch through the underbody. Whenever the body is moved in relation to the frame, disconnect the intermediate shaft from the rack and pinion steering gear and stub shaft. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the intermediate shaft from the steering gear stub shaft. Refer to Intermediate Steering Shaft Replacement in Power Steering System. 3. Install a utility stand to the rear of the frame. 4. Remove the rear frame bolts. 5. Lower the rear of the frame. 6. Remove the upper and lower insulators from the rear of the frame as a set. Installation Procedure 1. Apply lube to inside surface of lower insulator and to top surface of upper insulator. 2. Install the upper and lower insulators to the rear of the frame as a set. 3. Raise the rear of the frame. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Service and Repair > Drivetrain and Front Suspension Frame Front Insulator Replacement > Page 11783 Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the rear frame bolts. Tighten the rear frame bolts to 180 Nm (133 lb ft). 5. Remove the utility stand. 6. Install the intermediate shaft to the steering gear stub shaft. Refer to Intermediate Steering Shaft Replacement in Power Steering System. 7. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Procedures Arm Rest: Procedures Armrest Pull Cup Replacement Armrest Pull Cup Replacement REMOVAL PROCEDURE 1. Remove the screws from the front and/or rear door armrest pull cup NOTE: Apply protective coating/tape at the insertion point of the small flat-bladed tool in order to prevent damage to the inner door trim panel. 2. Remove the front and/or rear door armrest pull cup from the inner door trim panel using a small flat-bladed tool at the front of the front and/or rear door armrest pull cup and press rearward in order to release the clip retainer. 3. Remove the front and/or rear door armrest pull cup from the front and/or rear inner door trim pane. 4. Remove the front door power mirror switch from the front door armrest pull cup. 5. Remove the front and/or rear door power window switch from the front and/or rear door armrest pull cup. ^ For the front door refer to Power Window Switch Replacement (Impala) or Power Window Switch Replacement (Monte Carlo) ^ For the rear door refer to Rear Door Power Window Switch Replacement (Impala). INSTALLATION PROCEDURE 1. Install the front door power mirror switch to the front door armrest pull cup. 2. Install the front and/or rear door armrest power window switch to the front and/or rear door armrest pull cup. ^ For the front door refer to Power Window Switch Replacement (Impala) or Power Window Switch Replacement (Monte Carlo). ^ For the rear door refer to Rear Door Power Window Switch Replacement (Impala). 3. Install the front and/or rear door armrest pull cup to the front and/or rear inner door trim panel pressing into place until fully seated. 4. Install the screws to the front and/or rear door armrest pull cup Tighten Tighten the screws to the front and/or rear door armrest pull cup to 6 N.m (53 lb in). Console Armrest Replacement - Front Floor Console Armrest Replacement - Front Floor REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Procedures > Page 11789 1. Raise the front floor console armrest. 2. Remove the screws from the front floor console armrest hinge at the front floor console armrest. 3. Remove the front floor console armrest from the front floor console. INSTALLATION PROCEDURE 1. Install the front floor console armrest to the hinge at the front floor console. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Procedures > Page 11790 2. Install the screws to the front floor console armrest hinge. Tighten Tighten the front floor console armrest hinge screws to 2 N.m (18 lb in). 3. Lower the front floor console armrest. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Procedures > Page 11791 Arm Rest: Removal and Replacement Armrest Pull Cup Replacement Armrest Pull Cup Replacement (Impala) Removal Procedure 1. Remove the screws from the front and/or rear door armrest pull cup Notice: Apply protective coating/tape at the insertion point of the small flat-bladed tool in order to prevent damage to the inner door trim panel. 2. Remove the front and/or rear door armrest pull cup from the inner door trim panel using a small flat-bladed tool at the front of the front and/or rear door armrest pull cup and press rearward in order to release the clip retainer. 3. Remove the front and/or rear door armrest pull cup from the front and/or rear inner door trim panel. 4. Remove the front door power mirror switch from the front door armrest pull cup. 5. Remove the front and/or rear door power window switch from the front and/or rear door armrest pull cup. Installation Procedure 1. Install the front door power mirror switch to the front door armrest pull cup. Refer to Power Mirror Switch Replacement (Impala). 2. Install the front and/or rear door armrest power window switch to the front and/or rear door armrest pull cup. 3. Install the front and/or rear door armrest pull cup to the front and/or rear inner door trim panel pressing into place until fully seated. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the screws to the front and/or rear door armrest pull cup Tighten the screws to the front and/or rear door armrest pull cup to 6 Nm (53 lb in). Front Floor Console Armrest Replacement Front Floor Console Armrest Replacement Removal Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Procedures > Page 11792 1. Raise the front floor console armrest. 2. Remove the screws from the console armrest hinge. 3. Remove the console armrest. Installation Procedure 1. Install the armrest to the hinge at the front floor console. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws to console armrest hinge. Tighten the screws to 2 Nm (18 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Procedures > Page 11793 3. Lower the console armrest. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Technical Service Bulletins > Customer Interest for Ash Tray: > 04-08-49-031 > Dec > 04 > Interior - Ash Tray Will Not Open Ash Tray: Customer Interest Interior - Ash Tray Will Not Open Bulletin No.: 04-08-49-031 Date: December 07, 2004 TECHNICAL Subject: Ash Tray Will Not Open (Reposition Ash Tray Reflector Flap, Replace Ash Tray, if Necessary) Models: 2000-2004 Chevrolet Impala Condition Some customers may comment that the ash tray housing will not open. Cause This condition may be caused by the ash tray reflector flap folded forward causing the ash tray not to open. Correction Remove and reinstall the ash tray. 1. Open the ash tray as seen in the illustration above. 2. Push the ash tray forward and hold the reflector flap down with a screw driver as seen in the illustration above. Pull rearward. This will allow the ash tray reflector flap to pass by the housing and fully open. 3. Replace the ash tray receptacle if damaged. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Technical Service Bulletins > Customer Interest for Ash Tray: > 04-08-49-031 > Dec > 04 > Interior - Ash Tray Will Not Open > Page 11802 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ash Tray: > 04-08-49-031 > Dec > 04 > Interior - Ash Tray Will Not Open Ash Tray: All Technical Service Bulletins Interior - Ash Tray Will Not Open Bulletin No.: 04-08-49-031 Date: December 07, 2004 TECHNICAL Subject: Ash Tray Will Not Open (Reposition Ash Tray Reflector Flap, Replace Ash Tray, if Necessary) Models: 2000-2004 Chevrolet Impala Condition Some customers may comment that the ash tray housing will not open. Cause This condition may be caused by the ash tray reflector flap folded forward causing the ash tray not to open. Correction Remove and reinstall the ash tray. 1. Open the ash tray as seen in the illustration above. 2. Push the ash tray forward and hold the reflector flap down with a screw driver as seen in the illustration above. Pull rearward. This will allow the ash tray reflector flap to pass by the housing and fully open. 3. Replace the ash tray receptacle if damaged. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ash Tray: > 04-08-49-031 > Dec > 04 > Interior - Ash Tray Will Not Open > Page 11808 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Locations > Ashtray Assembly Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Locations > Ashtray Assembly > Page 11811 Ash Tray: Locations Ashtray Lamp Center console, below the ashtray. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Procedures Ash Tray: Procedures Ashtray Replacement Ashtray Replacement REMOVAL PROCEDURE 1. Remove the instrument panel cluster trim plate. 2. Remove the instrument panel ashtray. 3. Remove the instrument panel ashtray bracket screws (1). 4. Remove the instrument panel ashtray bracket from the instrument panel. 5. Disconnect the electrical connector from the ashtray. INSTALLATION PROCEDURE 1. Connect the electrical connector to the ashtray. 2. Install the instrument panel ashtray bracket to the instrument panel. 3. Install the instrument panel ashtray bracket screws (1). Tighten Tighten the instrument panel ashtray bracket screws (1) to 2 N.m (18 lb in). 4. Install the instrument panel ashtray. 5. Install the instrument panel cluster trim plate. Console Ashtray/Lighter Replacement (Front) Console Ashtray/Lighter Replacement (Front) REMOVAL PROCEDURE TOOLS REQUIRED J 42059 Cigarette Lighter Socket Remover 1. Remove the cigarette lighter fuse. 2. Remove the cigarette lighter element. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Procedures > Page 11814 3. Remove the cigarette lighter socket by placing one side of the T portion of the tool J 42059 into the tab window and then the other should be angled into the opposite tab window, then pull the lighter socket straight out. 4. Remove the tool from the lighter socket. 5. Disconnect the electrical connector from the cigarette lighter socket. 6. Remove the cigarette lighter retainer using your index finger and pulling out. INSTALLATION PROCEDURE 1. Position the cigarette lighter retainer with the key to the slot into the cigarette lighter hole. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Procedures > Page 11815 2. Install the cigarette lighter retainer pressing into place until fully seated. 3. Connect the electrical connector to cigarette lighter socket. 4. Align the cigarette lighter socket to the to the cigarette lighter retainer. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Procedures > Page 11816 5. Press the cigarette lighter socket into place until fully seated. 6. Install the cigarette lighter element. 7. Install the cigarette lighter fuse. 8. Inspect the instrument panel lighter for proper operation. Console Ashtray/Lighter Replacement (Rear) Console Ashtray/Lighter Replacement (Rear) REMOVAL PROCEDURE 1. Open the ashtray. 2. Depress the retainer at the top middle of the ashtray while pulling the ashtray rearward. 3. Remove the ashtray. INSTALLATION PROCEDURE 1. Depress the retainer at the top middle of the ashtray. Install the ashtray into the opening in the floor console. 2. Close the ashtray. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Procedures > Page 11817 Ash Tray: Removal and Replacement Ashtray Replacement Ashtray Replacement Replacement Procedure 1. Remove the instrument panel (IP) cluster trim plate. Refer to Instrument Panel Cluster Trim Plate Bezel Replacement (Impala) (See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cluster Trim Plate Bezel Replacement)Instrument Panel Cluster Trim Plate Bezel Replacement (Monte Carlo) (See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cluster Trim Plate Bezel Replacement). 2. Remove the IP ashtray. 3. Remove the IP ashtray bracket screws (1). 4. Remove the IP ashtray bracket. 5. Disconnect the electrical connector from the ashtray. Installation Procedure 1. Connect the electrical connector to the ashtray. 2. Install the IP ashtray bracket to the instrument panel. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the IP ashtray bracket screws (1). Tighten the screws to 2 Nm (18 lb in). 4. Install the IP ashtray. 5. Install the IP cluster trim plate. Refer to Instrument Panel Cluster Trim Plate Bezel Replacement (Impala) (See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cluster Trim Plate Bezel Replacement)Instrument Panel Cluster Trim Plate Bezel Replacement (Monte Carlo) (See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cluster Trim Plate Bezel Replacement). Console Ashtray/Lighter Replacement Console Ashtray/Lighter Replacement Tools Required Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Procedures > Page 11818 J 42059 Cigarette Lighter Socket Remover Removal Procedure 1. Remove the cigarette lighter fuse. 2. Remove the cigarette lighter element. 3. Remove the cigarette lighter socket by placing one side of the T portion of J 42059 into the tab window. Angle the other side of the tool into the opposite tab window. Pull the lighter socket straight out. 4. Remove J 42059 from the lighter socket. 5. Disconnect the electrical connector from the cigarette lighter socket. 6. Using your index finger, pull out the cigarette lighter retainer. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Procedures > Page 11819 1. Position the cigarette lighter retainer with J 42059 to the slot into the cigarette lighter hole. 2. Install the cigarette lighter retainer. Press the retainer into place until fully seated. 3. Connect the electrical connector to the cigarette lighter socket. 4. Align the cigarette lighter socket to the cigarette lighter retainer. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Procedures > Page 11820 5. Press the cigarette lighter socket into place until fully seated. 6. Install the cigarette lighter element. 7. Install the cigarette lighter fuse. 8. Inspect the IP lighter for proper operation. Front Floor Console Rear Ashtray Replacement Front Floor Console Rear Ashtray Replacement Removal Procedure 1. Open the ashtray. 2. Depress the retainer at the top middle of the ashtray while pulling the ashtray rearward. 3. Remove the ashtray. Installation Procedure 1. Depress the retainer at the top middle of the ashtray. Install the ashtray into the opening in the floor console. 2. Close the ashtray. Front Seat Ashtray and Housing Replacement Front Seat Ashtray and Housing Replacement (Impala) Removal Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Procedures > Page 11821 1. Open the ashtray. 2. Depress the ashtray retainer. 3. Remove the ashtray from the ashtray housing. 4. Remove the ashtray housing, by pressing down with your thumbs and pulling out from the armrest housing base. Installation Procedure 1. Position the ashtray housing to the armrest base. 2. Install the ashtray housing, pressing into place until fully seated. 3. Install the ashtray, pressing into place until fully seated. 4. Close the ashtray. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats Carpet: Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 11826 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 11827 Carpet: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 11828 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 11829 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Front Side Door Opening Floor Carpet Retainer Replacement Carpet: Service and Repair Front Side Door Opening Floor Carpet Retainer Replacement Front Side Door Opening Floor Carpet Retainer Replacement Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Remove the front door opening carpet retainer using J 38778 . 2. Remove the front door opening carpet retainer from the vehicle. Installation Procedure 1. Align the front door opening carpet retainer to the push-in nuts and to the front door weatherstripping. 2. Install the door opening carpet retainer to the push-in nuts, applying pressure to secure at all tab locations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Front Side Door Opening Floor Carpet Retainer Replacement > Page 11832 Carpet: Service and Repair Rear Side Door Opening Floor Carpet Retainer Replacement Rear Side Door Opening Floor Carpet Retainer Replacement Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure Use the J 38778 to remove the left and/or right rear carpet retainer. Installation Procedure Install the left and/or right rear carpet retainer. Apply force until the carpet retainer is fully seated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Front Side Door Opening Floor Carpet Retainer Replacement > Page 11833 Carpet: Service and Repair Front Floor Panel Carpet Replacement Front Floor Panel Carpet Replacement Removal Procedure 1. Remove the front seats. Refer to Split Bench Seat Replacement (See: Seats/Service and Repair/Split Bench Seat Replacement) or to Front Seat Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket) in Seats: 2. Remove the front floor center console, if equipped. Refer to Front Floor Console Replacement (Impala) (See: Console/Service and Repair/Front Floor Console Replacement)Front Floor Console Replacement (Monte Carlo) (See: Console/Service and Repair/Front Floor Console Replacement) in Instrument Panel, Gages and Console. 3. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Seats/Seat Cushion/Service and Repair/Rear Seat Cushion Replacement) in Seats. 4. Remove the carpet retainers. Refer to Front Side Door Opening Floor Carpet Retainer Replacement (See: Front Side Door Opening Floor Carpet Retainer Replacement) and to Rear Side Door Opening Floor Carpet Retainer Replacement (See: Rear Side Door Opening Floor Carpet Retainer Replacement). 5. For the Impala, remove the center pillar lower trim panel. Refer to Center Pillar Lower Trim Panel Replacement (Impala) (See: Trim Panel/Service and Repair/Center Pillar Lower Trim Panel Replacement). 6. Remove the rear lower quarter trim panel. Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Trim Panel/Service and Repair/Quarter Lower Rear Trim Panel Replacement)Quarter Lower Rear Trim Panel Replacement (Monte Carlo) (See: Trim Panel/Service and Repair/Quarter Lower Rear Trim Panel Replacement). 7. Remove the carpet from the vehicle. Installation Procedure Caution: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Install the carpet into the vehicle. Reach under the carpet and feed the power seat adjusters, vacuum connector and seat belt warning wire connector through the slits in the carpet where required. 2. Install the rear quarter lower trim. Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Trim Panel/Service and Repair/Quarter Lower Rear Trim Panel Replacement)Quarter Lower Rear Trim Panel Replacement (Monte Carlo) (See: Trim Panel/Service and Repair/Quarter Lower Rear Trim Panel Replacement). 3. For the Impala, install the center pillar lower trim panel. Refer to Center Pillar Lower Trim Panel Replacement (Impala) (See: Trim Panel/Service and Repair/Center Pillar Lower Trim Panel Replacement). 4. Install the carpet retainers. Refer to Front Side Door Opening Floor Carpet Retainer Replacement (See: Front Side Door Opening Floor Carpet Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Front Side Door Opening Floor Carpet Retainer Replacement > Page 11834 Retainer Replacement) and to Rear Side Door Opening Floor Carpet Retainer Replacement (See: Rear Side Door Opening Floor Carpet Retainer Replacement). 5. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Seats/Seat Cushion/Service and Repair/Rear Seat Cushion Replacement) in Seats. 6. Install the front floor center console, if equipped. Refer to Front Floor Console Replacement (Impala) (See: Console/Service and Repair/Front Floor Console Replacement)Front Floor Console Replacement (Monte Carlo) (See: Console/Service and Repair/Front Floor Console Replacement) in Instrument Panel, Gages, and Console. 7. Install the front seats. Refer to Split Bench Seat Replacement (See: Seats/Service and Repair/Split Bench Seat Replacement) or to Front Seat Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket) in Seats: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 03-08-49-018A > Apr > 04 > Interior - Console Lid Latch Broken Console: Customer Interest Interior - Console Lid Latch Broken Bulletin No.: 03-08-49-018A Date: April 20, 2004 TECHNICAL Subject: Broken Console or Storage Compartment Lid Latch (Replace Latch) Models: 1997-2004 Buick Century, Regal 2000-2004 Chevrolet Impala, Monte Carlo Supercede: This bulletin is being revised to add models and revise the Parts Information. Please discard Corporate Bulletin Number 03-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment on a broken console or storage compartment lid latch. Cause In most cases, customers are unaware of the latches proper operation and may apply excessive force to the lid. Additionally, the latch may take excessive force if the console is subjected to downward force such as being kneeled, or sat on. Correction Important: Replace only the latch. Do not replace the console lid and/or armrest assembly. Replace the latch. The latch assembly is sold as a separate part for the vehicles listed above. The latch is retained by two screws in the latch assembly. Parts Information Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 03-08-49-018A > Apr > 04 > Interior - Console Lid Latch Broken > Page 11843 Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 03-08-49-018A > Apr > 04 > Interior - Console Lid Latch Broken Console: All Technical Service Bulletins Interior - Console Lid Latch Broken Bulletin No.: 03-08-49-018A Date: April 20, 2004 TECHNICAL Subject: Broken Console or Storage Compartment Lid Latch (Replace Latch) Models: 1997-2004 Buick Century, Regal 2000-2004 Chevrolet Impala, Monte Carlo Supercede: This bulletin is being revised to add models and revise the Parts Information. Please discard Corporate Bulletin Number 03-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment on a broken console or storage compartment lid latch. Cause In most cases, customers are unaware of the latches proper operation and may apply excessive force to the lid. Additionally, the latch may take excessive force if the console is subjected to downward force such as being kneeled, or sat on. Correction Important: Replace only the latch. Do not replace the console lid and/or armrest assembly. Replace the latch. The latch assembly is sold as a separate part for the vehicles listed above. The latch is retained by two screws in the latch assembly. Parts Information Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 03-08-49-018A > Apr > 04 > Interior - Console Lid Latch Broken > Page 11849 Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Page 11850 Console: Specifications Front Floor Console Armrest Hinge Screw 2 Nm Front Floor Console Bolt 12 Nm Front Floor Console Trim Plate screws 2 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement - Front Floor Console: Service and Repair Console Replacement - Front Floor Console Replacement - Front Floor REMOVAL PROCEDURE 1. Remove the front floor console trim plate. 2. Remove the front floor console bolts: ^ Near the instrument panel (IP) ^ At the transaxle shift control lever ^ Under the mat in the rear bin 3. Pull the console rearward in order to disengage the clips from the IP. 4. Disconnect the electrical connectors. 5. Remove the front floor console. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement - Front Floor > Page 11853 1. Position the front floor console to the vehicle. 2. Connect the electrical connectors. 3. Install the front floor console. Engage the clips at the instrument panel (IP). 4. Install the front floor console bolts: ^ Near the instrument panel (IP) ^ At the transaxle shift control lever ^ Under the mat in the rear bin Tighten Tighten the front floor console bolts to 12 N.m (106 lb in). 5. Install the front floor console trim plate. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement - Front Floor > Page 11854 Console: Service and Repair Front Floor Console Replacement Front Floor Console Replacement (Impala) Removal Procedure 1. Remove the trim plate from the front floor console. Refer to Front Floor Console Trim Plate Replacement (Impala) (See: Front Floor Console Trim Plate Replacement). 2. Remove the following front floor console bolts: * Near the instrument panel (IP) * At the transaxle shift control lever * Under the mat in the rear bin 3. Pull the console rearward in order to disengage the clips from the IP. 4. Disconnect the electrical connectors. 5. Remove the front floor console. Installation Procedure 1. Position the front floor console to the vehicle. 2. Connect the electrical connectors. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement - Front Floor > Page 11855 3. Install the front floor console. Engage the clips at the IP. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the following front floor console bolts: * Near the instrument panel (IP) * At the transaxle shift control lever * Under the mat in the rear bin Tighten the bolts to 12 Nm (106 lb in). 5. Install the trim plate to the front floor console. Refer to Front Floor Console Trim Plate Replacement (Impala) (See: Front Floor Console Trim Plate Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement - Front Floor > Page 11856 Console: Service and Repair Front Floor Console Trim Plate Replacement Front Floor Console Trim Plate Replacement (Impala) Removal Procedure 1. Apply the park brake. 2. Adjust the automatic transaxle shift control indicator to 2. 3. Open the storage compartment door. 4. Carefully pry the rear of the trim plate away from the front floor console. 5. Pull the trim plate towards the rear of the vehicle in order to disengage the front of the trim plate. 6. Remove the console shift control bezel. 7. Disconnect the electrical connector at the rear of the front floor console trim plate. 8. Rotate the trim plate 180 degrees. Lift the trim plate over the shift control handle. 9. Disconnect the wiring harness retainers from the trim plate. 10. Disconnect the ashtray lamp and the wiring harness. 11. Disconnect the cigar lighter electrical connector. 12. Remove the ashtray. 13. Remove the front floor console trim plate. Installation Procedure 1. Install the front floor console trim plate. 2. Install the ashtray. 3. Connect the cigar lighter electrical connector. 4. Install the ashtray lamp and the wiring harness. 5. Connect the wiring harness retainers to the trim plate. 6. Lower the trim plate over the shift control handle. Rotate the trim plate 180 degrees. 7. Connect the electrical connector at the rear of the trim plate. 8. Install the console shift control bezel. 9. Engage the trim plate. Ensure that the retainers are completely engaged. 10. Close the storage compartment door. 11. Place the automatic transaxle shift control indicator in Park. 12. Release the park brake. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement - Front Floor > Page 11857 Console: Service and Repair Roof Console Replacement Roof Console Replacement Removal Procedure 1. Remove the screw from the overhead console. 2. Use a small, flat-bladed tool in order to release the 2 retainers. These retainers are located on each side of the assembly in front of the switches. Press the retainers outward to release the assembly. 3. Remove the overhead console from the headliner. 4. Disconnect the electrical connectors from the overhead console. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement - Front Floor > Page 11858 5. Remove the overhead console from the vehicle. 6. Remove the screws from the drivers information center module. 7. Remove the drivers information center module from the overhead console. Installation Procedure 1. Install the drivers information center module to the overhead console. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the drivers information center module screws. Tighten the screws to 2 Nm (18 lb in). Important: When installing the overhead console, apply a foam type tape to the wiring harness to relocate and secure the wiring harness in the proper position to the headliner. 3. Apply foam tape to the wiring harness at the headliner. 4. Connect the electrical connector to the overhead console. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement - Front Floor > Page 11859 5. Position the overhead console to the mounting bracket in the headliner. 6. Install the overhead console pressing into place in order to fully seat the retainer tabs. 7. Install the screw to the overhead console. Tighten the screw to 2 Nm (18 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement - Front Floor > Page 11860 Console: Service and Repair Trim Plate Replacement - Front Floor Console REMOVAL PROCEDURE 1. Apply the parking brake. 2. Adjust the automatic transaxle shift control indicator to 2. 3. Open the storage compartment door. 4. Carefully pry the rear of the front floor console trim plate away from the floor console. 5. Pull the front floor console trim plate towards the rear of the vehicle in order to disengage the front of the trim plate. 6. Remove the console shift control bezel. 7. Disconnect the electrical connector at the rear of the floor console trim plate. 8. Rotate the trim plate 180 degrees. Lift the trim plate over the shift control handle. 9. Disconnect the wiring harness retainers from the trim plate. 10. Disconnect the ashtray lamp and wiring harness. 11. Disconnect the cigar lighter electrical connector. 12. Remove the ashtray. 13. Remove the front floor console trim plate. INSTALLATION PROCEDURE 1. Install the ashtray. 2. Connect the cigar lighter electrical connector. 3. Install the ashtray lamp and wiring harness. 4. Connect the wiring harness retainers to the trim plate. 5. Lower the front floor console trim plate over the shift control handle. Rotate the trim plate 180 degrees. 6. Connect the electrical connector at the rear of the floor console trim plate. 7. Install the console shift control bezel. 8. Install the front floor console trim plate. Ensure the retainers are completely engaged. 9. Close the storage compartment door. 10. Place the automatic transaxle shift control indicator in Park. 11. Push to release the parking brake. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions CAUTION: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserve energy supply. The reserve energy supply provides deployment power for the air bags. Deployment power is available for as much as 10 seconds after disconnecting the vehicle power by any of the following methods: ^ Turn OFF the ignition. ^ Remove the fuse that provides power to the SDM. ^ Disconnect the vehicle battery from the vehicle electrical system. Disabling the SIR system prevents deploying of the air bags from the reserve energy supply power. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the LH instrument panel access hole cover. 5. Remove the SDM Fuse from the fuse block. IMPORTANT: With the SDM Fuse removed and the ignition ON, The AIR BAG warning lamp illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the RH instrument panel access hole cover. 7. Unclip the frontal air bags yellow 4-way connector from the metal rail. 8. Remove the Connector Position Assurance (CPA) from the frontal air bags yellow 4-way connector. 9. Disconnect the frontal air bags yellow 4-way connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 11867 10. Remove the connector position assurance (CPA) from the driver side air bag yellow 2-way connector (4) located under the driver seat, if the vehicle is equipped with a driver side air bag. 11. Disconnect the driver side air bag yellow 2-way connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 11868 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Connect the driver side air bag yellow 2-way connector (4) located under the driver seat, if the vehicle is equipped with a driver side air bag. 2. Install the CPA to the driver side air bag yellow 2-way connector. 3. Connect the frontal air bags yellow 4-way connector located at the RH side of the instrument panel. 4. Install the CPA to the frontal air bags yellow 4-way connector. 5. Connect the frontal air bags yellow 4-way connector to the metal rail. 6. Instal the RH instrument panel access hole cover. 7. Install the SDM fuse to the LH fuse block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 11869 8. Install the LH instrument panel access hole cover. 9. Staying well away from the airbags, turn ON the ignition. 9.1. The AIR BAG warning lamp will flash seven times. 9.2. The AIR BAG warning lamp will then turn OFF. 10. Perform A Diagnostic System Check SIR if the AIR BAG warning lamp does not operate as described. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair Drink Holders: Service and Repair Front Seat Armrest Cup Holder Replacement Removal Procedure 1. Open the armrest lid. 2. Rotate the cup holder to its open position. 3. Squeeze the mounting bracket of the cup holder assembly together to disengage the pins from the armrest storage box sides. 4. Remove the cup holder. Installation Procedure 1. Position the cup holder in the armrest. 2. Squeeze the mounting bracket of the cup holder assembly and insert the pins into the mounting holes. 3. Rotate the cup holder to its closed position. 4. Close the armrest lid. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Service and Repair Glove Compartment Lock Cylinder: Service and Repair Instrument Panel Compartment Door Lock Cylinder Replacement Removal Procedure 1. Open the instrument panel (IP) compartment door. 2. Remove the screws from the inner door panel to the IP compartment. 3. Separate the inner and the outer door panels. Position the inner door panel to the closed position and the outer door panel to the open position. 4. Remove the retainer clip from the door handle latch mechanism by sliding out. 5. Remove the door handle latch mechanism from the outer door panel. 6. Insert the key into the IP compartment door lock cylinder. 7. Insert a small diameter tool into the slot on the side of the door handle cylinder housing. 8. Depress the tool into the lock cylinder slot and turn the key 1/4-turn clockwise. Important: Note the position of the lock cylinder on removal for installation. 9. Pull the lock cylinder from the door handle cylinder housing. Installation Procedure 1. Insert the key into the lock cylinder. 2. Align the lock cylinder in the same position used for removal. 3. Install the lock cylinder to the door handle cylinder housing. Press into place until fully seated. 4. Turn the key 1/4-turn counterclockwise in order to secure the lock cylinder retainer. 5. Remove the key from the lock cylinder. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Service and Repair > Page 11877 6. Install the latch mechanism to the IP compartment door handle. 7. Position the inner and the outer door panels together. Notice: Refer to Fastener Notice in Cautions and Notices. 8. Install the screws to the inner IP compartment door panel. Tighten the panel screws to 2 Nm (18 lb in). 9. Inspect the lock cylinder for proper operation. 10. Close the IP compartment door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 02-08-67-001 > Feb > 02 > Headliner - Sags At Sunroof Opening Headliner: Customer Interest Headliner - Sags At Sunroof Opening File In Section: 08 - Body and Accessories Bulletin No.: 02-08-67-001 Date: February, 2002 TECHNICAL Subject: Headliner Sags At Sunroof Opening (Reattach Velcro(R) Strips) Models: 2000-2001 Chevrolet Impala Condition Some customers may comment that the headliner sags at the front of the sunroof opening. Cause The Velcro(R) strips may have come loose from the sunroof module and/or the headliner. Correction Replace the Velcro(R) strips that may have pulled loose from the sunroof module and/or the headliner. Clean the surface of the sunroof module using one of the cleaners listed below. Make sure the two halves of the Velcro(R) strips are properly aligned with each other before reattaching them. Apply adhesion promoter, P/N 12378462 (in Canada, us 10953554), to the sunroof module to improve the 3M(R) Dual Lock(TM) strip retention. If the Velcro(R) strips have come loose from the headliner, use hot melt glue to reattach them. Parts Information Parts are currently available from GMSPO. To obtain 3M(R) Dual Lock(TM) Mini-Pack, purchase it locally. Cleaning Solvents ^ 3M(R) General Purpose Adhesive Cleaner, P/N 08984 ^ Dominion Sure Seal, Sure Solve Stock BSS ^ Kent Acrosol Warranty Information For vehicles repaired under warranty use the table as shown. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 02-08-67-001 > Feb > 02 > Headliner - Sags At Sunroof Opening > Page 11886 DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 02-08-67-001 > Feb > 02 > Headliner - Sags At Sunroof Opening Headliner: All Technical Service Bulletins Headliner - Sags At Sunroof Opening File In Section: 08 - Body and Accessories Bulletin No.: 02-08-67-001 Date: February, 2002 TECHNICAL Subject: Headliner Sags At Sunroof Opening (Reattach Velcro(R) Strips) Models: 2000-2001 Chevrolet Impala Condition Some customers may comment that the headliner sags at the front of the sunroof opening. Cause The Velcro(R) strips may have come loose from the sunroof module and/or the headliner. Correction Replace the Velcro(R) strips that may have pulled loose from the sunroof module and/or the headliner. Clean the surface of the sunroof module using one of the cleaners listed below. Make sure the two halves of the Velcro(R) strips are properly aligned with each other before reattaching them. Apply adhesion promoter, P/N 12378462 (in Canada, us 10953554), to the sunroof module to improve the 3M(R) Dual Lock(TM) strip retention. If the Velcro(R) strips have come loose from the headliner, use hot melt glue to reattach them. Parts Information Parts are currently available from GMSPO. To obtain 3M(R) Dual Lock(TM) Mini-Pack, purchase it locally. Cleaning Solvents ^ 3M(R) General Purpose Adhesive Cleaner, P/N 08984 ^ Dominion Sure Seal, Sure Solve Stock BSS ^ Kent Acrosol Warranty Information For vehicles repaired under warranty use the table as shown. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 02-08-67-001 > Feb > 02 > Headliner - Sags At Sunroof Opening > Page 11892 DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures Headliner: Procedures Headlining Trim Panel Replacement (Impala) Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal 1. Remove the sunshades. 2. Remove the sunshade anchors. 3. Remove the dome lamp, if equipped. 4. Remove the overhead console, if equipped. 5. Remove the assist handles, if equipped. 6. Remove the coat hook. 7. Remove the side rail lamps, if equipped. 8. Remove the windshield pillar garnish molding. 9. Remove the rear seat back. 10. Remove the rear window trim panel. 11. Remove the upper quarter trim panels. 12. Remove the center pillar upper trim panels. 13. Remove the push-in retainers from the rear of the headliner using J 38778 . Use help from an assistant in order to support the front of the headliner. 14. Disconnect the headliner electrical connector and the ground wire. 15. Remove the headliner wiring harness from the inner roof panel. 16. Recline the front seats in order to aid in the removal of the headliner from the vehicle. 17. Remove the headliner (without sunroof) from the roof insulator pad, using a flat-bladed tool to cut through the glue bonding the headliner to the roof insulator pad. 18. Remove the headliner (with sunroof) from the sunroof module by disengaging the velcro strips. 19. Remove the headliner from the vehicle through the right front door, with an assistant. Installation Important: Do not bend the headlining too much when loading the headliner in to the vehicle. 1. Move the headliner into the vehicle through the right front door, with an assistant. 2. Position the headliner to the roof by aligning the sunshade holes in the headliner with the respective hole in the roof structure. 3. Connect the headliner electrical connector and the ground wire. 4. Install the headliner wiring harness to the inner roof panel. 5. Install the sunshades. 6. Install the sunshade anchors. 7. Install the two rear push-in retainers to the rear of the headliner. 8. Install the headliner (with sunroof) to the sunroof module by engaging the velcro strips. 9. Install the center pillar upper trim panels. 10. Install the rear quarter upper trim panels. 11. Install the windshield pillar garnish molding. 12. Install the side rail lamps, if equipped. 13. Install the assist handle, if equipped. 14. Install the overhead console, if equipped. 15. Install the coat hook. 16. Install the dome lamp, if equipped. 17. Install the rear window trim panel. 18. Install the rear seat back. - For the non folding rear seat, refer to Seat Back Replacement. - For the folding rear seat, refer to Seat Back Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 11895 Headliner: Removal and Replacement Headlining Trim Panel Replacement (Impala) Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the sunshades. Refer to Sunshade Replacement (See: Sun Visor/Service and Repair/Sunshade Replacement). 2. Remove the sunshade anchors. Refer to Sunshade Anchor Replacement (See: Sun Visor/Service and Repair/Sunshade Anchor Replacement). 3. Remove the dome lamp, if equipped. Refer to Dome Lamp Replacement (Impala and Monte Carlo) Dome Lamp Replacement (Impala with SEO, RPO 6C7) . 4. Remove the overhead console, if equipped. Refer to Roof Console Replacement (See: Console/Service and Repair/Roof Console Replacement). 5. Remove the assist handles, if equipped. Refer to Assist Handle Replacement (Impala Front) (See: Passenger Assist Handle/Service and Repair). 6. Remove the coat hook. Refer to Coat Hook Replacement (See: Service and Repair). 7. Remove the side rail lamps, if equipped. Refer to Roof Side Rail Lamp Replacement . 8. Remove the windshield pillar garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (Impala) (See: Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). 9. Remove the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)) in Seats. 10. Remove the rear window trim panel. Refer to Rear Window Shelf Trim Panel Replacement (Impala) (See: Trim Panel/Service and Repair/Rear Window Shelf Trim Panel Replacement) in Interior Trim. 11. Remove the upper quarter trim panels. Refer to Quarter Upper Trim Panel Replacement (Impala) (See: Trim Panel/Service and Repair/Quarter Upper Trim Panel Replacement). 12. Remove the center pillar upper trim panels. Refer to Center Pillar Upper Trim Panel Replacement (Impala) (See: Trim Panel/Service and Repair/Center Pillar Upper Trim Panel Replacement). 13. Remove the push-in retainers from the rear of the headliner using J 38778 . Use help from an assistant in order to support the front of the headliner. 14. Disconnect the headliner electrical connector and the ground wire. 15. Remove the headliner wiring harness from the inner roof panel. 16. Recline the front seats in order to aid in the removal of the headliner from the vehicle. 17. Remove the headliner (without sunroof) from the roof insulator pad, using a flat-bladed tool to cut through the glue bonding the headliner to the roof insulator pad. 18. Remove the headliner (with sunroof) from the sunroof module by disengaging the velcro strips. 19. Remove the headliner from the vehicle through the right front door, with an assistant. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 11896 Important: Do not bend the headlining too much when loading the headliner in to the vehicle. 1. Move the headliner into the vehicle through the right front door, with an assistant. 2. Position the headliner to the roof by aligning the sunshade holes in the headliner with the respective hole in the roof structure. 3. Connect the headliner electrical connector and the ground wire. 4. Install the headliner wiring harness to the inner roof panel. 5. Install the sunshades. Refer to Sunshade Replacement (See: Sun Visor/Service and Repair/Sunshade Replacement). 6. Install the sunshade anchors. Refer to Sunshade Anchor Replacement (See: Sun Visor/Service and Repair/Sunshade Anchor Replacement). 7. Install the two rear push-in retainers to the rear of the headliner. 8. Install the headliner (with sunroof) to the sunroof module by engaging the velcro strips. 9. Install the center pillar upper trim panels. Refer to Center Pillar Upper Trim Panel Replacement (Impala) (See: Trim Panel/Service and Repair/Center Pillar Upper Trim Panel Replacement). 10. Install the rear quarter upper trim panels. Refer to Quarter Upper Trim Panel Replacement (Impala) (See: Trim Panel/Service and Repair/Quarter Upper Trim Panel Replacement. 11. Install the windshield pillar garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (Impala) (See: Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). 12. Install the side rail lamps, if equipped. Refer to Roof Side Rail Lamp Replacement . 13. Install the assist handle, if equipped. Refer to Assist Handle Replacement (Impala Front) (See: Passenger Assist Handle/Service and Repair). 14. Install the overhead console, if equipped. Refer to Roof Console Replacement (See: Console/Service and Repair/Roof Console Replacement). 15. Install the coat hook. Refer to Coat Hook Replacement (See: Service and Repair). 16. Install the dome lamp, if equipped. Refer to Dome Lamp Replacement (Impala and Monte Carlo) Dome Lamp Replacement (Impala with SEO, RPO 6C7) . 17. Install the rear window trim panel. Refer to Rear Window Shelf Trim Panel Replacement (Impala) (See: Trim Panel/Service and Repair/Rear Window Shelf Trim Panel Replacement) in Interior Trim. 18. Install the rear seat back. * For the non folding rear seat, refer to Seat Back Replacement - Rear (Non Folding Rear Seat) in Seats. * For the folding rear seat, refer to Seat Back Replacement - Rear (Folding Rear Seat) in Seats. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair Passenger Assist Handle: Service and Repair Assist Handle Replacement (Impala Front) Removal Procedure 1. Remove the plastic cover with a small, flat-bladed tool in order to expose the screws. 2. Pull down on the assist strap to expose the screws. 3. Remove the assist strap screws (1). 4. Remove the assist strap from the vehicle. Installation Procedure 1. Install the assist strap to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the assist strap screws (1). Tighten the assist strap screws to 2 Nm (18 lb in). 3. Install the plastic cover pressing into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Locations Rear Shelf: Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Locations > Page 11903 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sunshade Replacement Sun Visor: Service and Repair Sunshade Replacement Sunshade Replacement Removal Procedure The sunshades can be equipped with an illuminated vanity mirror. The illuminated vanity mirror is not serviced as a separate unit. 1. Position the sunshade so the bottom edge is pointing straight down. 2. Remove the sunshade from the sunshade anchor and position the sunshade between the sunshade anchor and the windshield. 3. Remove the screws from the sunshade. 4. Once the retainer shaft releases the sunshade will begin to separate from the bezel. Some back-and-forth movement may be necessary to release sunshade from the retainer. 5. Disconnect the electrical connector from the sunshade if equipped. 6. Remove the sunshade from the vehicle. Installation Procedure 1. Connect the electrical to the sunshade connector if equipped. 2. Position the sunshade to the mounting point at the roof. 3. Position the sunshade just behind the sunshade anchor. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the sunshade screws. Tighten the sunshade screws to 2 Nm (18 lb in). 5. Position the sunshade into the sunshade anchor. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sunshade Replacement > Page 11908 Sun Visor: Service and Repair Sunshade Anchor Replacement Sunshade Anchor Replacement Removal Procedure 1. Unhook the sunshade from the sunshade anchor. 2. Remove the screw from the sunshade anchor. 3. Remove the sunshade anchor from the roof. Installation Procedure 1. Position the sunshade anchor to the mounting position in the roof. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screw to the sunroof anchor. Tighten the sunroof anchor screw to 3 Nm (27 lb in). 3. Reposition the sunshade to the original position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Locations > DID Trim Panel Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Locations > DID Trim Panel > Page 11913 Trim Panel: Locations Door Armrest Trim Panel Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Locations > DID Trim Panel > Page 11914 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Locations > DID Trim Panel > Page 11915 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Lower Trim Panel Replacement Trim Panel: Service and Repair Center Pillar Lower Trim Panel Replacement Center Pillar Lower Trim Panel Replacement (Impala) Removal Procedure 1. Remove the front carpet retainer. Refer to Front Side Door Opening Floor Carpet Retainer Replacement (See: Carpet/Service and Repair/Front Side Door Opening Floor Carpet Retainer Replacement). 2. Remove the rear quarter lower trim panel. Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Quarter Lower Rear Trim Panel Replacement). 3. Remove the seat belt from the slot in the center lower trim panel. 4. Remove the center lower trim panel from the center pillar. Installation Procedure 1. Install the seat belt to the slot into the center lower trim panel. 2. Align the center lower trim panel to the center pillar. 3. Install the center lower trim panel push-in retainers, applying pressure at all push-in retainers locations until fully seated. 4. Install the rear quarter lower trim panel. Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Quarter Lower Rear Trim Panel Replacement). 5. Install the front door carpet retainer. Refer to Front Side Door Opening Floor Carpet Retainer Replacement (See: Carpet/Service and Repair/Front Side Door Opening Floor Carpet Retainer Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Lower Trim Panel Replacement > Page 11918 Trim Panel: Service and Repair Center Pillar Upper Trim Panel Replacement Center Pillar Upper Trim Panel Replacement (Impala) Removal Procedure 1. Remove the upper seat belt guide loop attachment from the adjuster bracket. * For the left front, refer to Seat Belt Retractor Replacement - Left Front (Impala) Seat Belt Retractor Replacement - Left Front (Monte Carlo) in Seat Belts. * for the right front, refer to Seat Belt Retractor Replacement - Right Front (Impala) Seat Belt Retractor Replacement - Right Front (Monte Carlo) in Seat Belts. 2. Pull out on the panel to disengage the retainer clip. 3. Remove the upper center pillar trim panel from the center pillar. Installation Procedure 1. Align the upper center pillar trim panel to the center pillar. 2. Install the upper center pillar trim panel by applying sufficed pressure engage the push-in retainers. 3. Install the upper seat belt upper guide loop attachment to the adjuster bracket. * For the left front, refer to Seat Belt Retractor Replacement - Left Front (Impala) Seat Belt Retractor Replacement - Left Front (Monte Carlo) in Seat Belts. * For the right front, refer to Seat Belt Retractor Replacement - Right Front (Impala) Seat Belt Retractor Replacement - Right Front (Monte Carlo) in Seat Belts. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Lower Trim Panel Replacement > Page 11919 Trim Panel: Service and Repair Convenience Net Replacement - Rear Compartment Convenience Net Replacement - Rear Compartment Removal Procedure 1. Open the rear compartment. 2. Remove the rear compartment convenience net from the retainers at the tail lamp wing nuts. 3. Remove the convenience net from the rear compartment. Installation Procedure 1. Install the rear compartment convenience net to the rear compartment. 2. Install the rear compartment convenience net to the retainers at the tail lamp wing nuts. 3. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Lower Trim Panel Replacement > Page 11920 Trim Panel: Service and Repair Quarter Lower Rear Trim Panel Replacement Quarter Lower Rear Trim Panel Replacement (Impala) Removal Procedure 1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Seats/Seat Cushion/Service and Repair/Rear Seat Cushion Replacement) in Seats. 2. Remove the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)) in Seats. 3. Pull out on the rear quarter upper trim panel to disengage the lower connector. Refer to Quarter Upper Trim Panel Replacement (Impala) (See: Quarter Upper Trim Panel Replacement). 4. Pull up to disengage the carpet retainer leg clip and out to disengage the quarter panel clips. 5. Slide the panel down and out from under the quarter upper panel. 6. Remove the rear quarter lower trim panel from the vehicle. Installation Procedure 1. Align the rear quarter lower trim panel push-in retainers to the rear quarter inner lower panel and to the rear door weatherstripping. 2. Install the rear quarter lower trim panel by applying pressure to secure at all push-in retainers locations. 3. Install the quarter upper trim panel. Refer to Quarter Upper Trim Panel Replacement (Impala) (See: Quarter Upper Trim Panel Replacement). 4. Install the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)) in Seats. 5. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Seats/Seat Cushion/Service and Repair/Rear Seat Cushion Replacement) in Seats. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Lower Trim Panel Replacement > Page 11921 Trim Panel: Service and Repair Center Pillar Lower Trim Panel Replacement Center Pillar Lower Trim Panel Replacement (Impala) Removal Procedure 1. Remove the front carpet retainer. Refer to Front Side Door Opening Floor Carpet Retainer Replacement (See: Carpet/Service and Repair/Front Side Door Opening Floor Carpet Retainer Replacement). 2. Remove the rear quarter lower trim panel. Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Quarter Lower Rear Trim Panel Replacement). 3. Remove the seat belt from the slot in the center lower trim panel. 4. Remove the center lower trim panel from the center pillar. Installation Procedure 1. Install the seat belt to the slot into the center lower trim panel. 2. Align the center lower trim panel to the center pillar. 3. Install the center lower trim panel push-in retainers, applying pressure at all push-in retainers locations until fully seated. 4. Install the rear quarter lower trim panel. Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Quarter Lower Rear Trim Panel Replacement). 5. Install the front door carpet retainer. Refer to Front Side Door Opening Floor Carpet Retainer Replacement (See: Carpet/Service and Repair/Front Side Door Opening Floor Carpet Retainer Replacement). Center Pillar Upper Trim Panel Replacement Center Pillar Upper Trim Panel Replacement (Impala) Removal Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Lower Trim Panel Replacement > Page 11922 1. Remove the upper seat belt guide loop attachment from the adjuster bracket. * For the left front, refer to Seat Belt Retractor Replacement - Left Front (Impala) Seat Belt Retractor Replacement - Left Front (Monte Carlo) in Seat Belts. * for the right front, refer to Seat Belt Retractor Replacement - Right Front (Impala) Seat Belt Retractor Replacement - Right Front (Monte Carlo) in Seat Belts. 2. Pull out on the panel to disengage the retainer clip. 3. Remove the upper center pillar trim panel from the center pillar. Installation Procedure 1. Align the upper center pillar trim panel to the center pillar. 2. Install the upper center pillar trim panel by applying sufficed pressure engage the push-in retainers. 3. Install the upper seat belt upper guide loop attachment to the adjuster bracket. * For the left front, refer to Seat Belt Retractor Replacement - Left Front (Impala) Seat Belt Retractor Replacement - Left Front (Monte Carlo) in Seat Belts. * For the right front, refer to Seat Belt Retractor Replacement - Right Front (Impala) Seat Belt Retractor Replacement - Right Front (Monte Carlo) in Seat Belts. Convenience Net Replacement - Rear Compartment Convenience Net Replacement - Rear Compartment Removal Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Lower Trim Panel Replacement > Page 11923 1. Open the rear compartment. 2. Remove the rear compartment convenience net from the retainers at the tail lamp wing nuts. 3. Remove the convenience net from the rear compartment. Installation Procedure 1. Install the rear compartment convenience net to the rear compartment. 2. Install the rear compartment convenience net to the retainers at the tail lamp wing nuts. 3. Close the rear compartment. Quarter Lower Rear Trim Panel Replacement Quarter Lower Rear Trim Panel Replacement (Impala) Removal Procedure 1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Seats/Seat Cushion/Service and Repair/Rear Seat Cushion Replacement) in Seats. 2. Remove the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)) in Seats. 3. Pull out on the rear quarter upper trim panel to disengage the lower connector. Refer to Quarter Upper Trim Panel Replacement (Impala) (See: Quarter Upper Trim Panel Replacement). 4. Pull up to disengage the carpet retainer leg clip and out to disengage the quarter panel clips. 5. Slide the panel down and out from under the quarter upper panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Lower Trim Panel Replacement > Page 11924 6. Remove the rear quarter lower trim panel from the vehicle. Installation Procedure 1. Align the rear quarter lower trim panel push-in retainers to the rear quarter inner lower panel and to the rear door weatherstripping. 2. Install the rear quarter lower trim panel by applying pressure to secure at all push-in retainers locations. 3. Install the quarter upper trim panel. Refer to Quarter Upper Trim Panel Replacement (Impala) (See: Quarter Upper Trim Panel Replacement). 4. Install the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)) in Seats. 5. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Seats/Seat Cushion/Service and Repair/Rear Seat Cushion Replacement) in Seats. Quarter Upper Trim Panel Replacement Quarter Upper Trim Panel Replacement (Impala) Removal Procedure 1. Remove the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)) in Seats. 2. Reposition the rear seat belt from the rear upper quarter trim panel. 3. Remove the rear upper quarter trim panel from the clip retainers on the upper side rail. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Lower Trim Panel Replacement > Page 11925 4. Remove the rear upper quarter trim panel from the rear quarter upper inner panel. 5. Remove the rear upper quarter trim panel from the vehicle. Installation Procedure 1. Install a new dual-lock retainer to the rear quarter inner panel, if required. 2. Align the rear quarter upper trim panel push-in retainers and the dual-lock retainer to the rear quarter inner upper panel. 3. Install the rear quarter upper trim panel push-in retainers, applying pressure to secure at all push-in retainers locations. 4. Align the rear quarter upper trim panel to the clip retainers on the upper side rail. 5. Install the rear quarter upper trim panel by applying sufficient pressure to all the upper side rail clip retainers locations until fully seated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Lower Trim Panel Replacement > Page 11926 6. Reposition the rear seat belt to the rear upper quarter trim panel. 7. Install the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)) in Seats. Rear Compartment Sill Trim Plate Replacement Rear Compartment Sill Trim Plate Replacement Removal Procedure 1. Open the rear compartment. 2. Pull up on the rear compartment sill plate to release the spring clips. 3. Remove the rear compartment sill plate from rear compartment. Installation Procedure 1. Align the spring clips to slots in rear compartment. 2. Press down on the rear compartment sill plate with even pressure until fully seated. 3. Close the rear compartment. Rear Compartment Trim Panel Replacement (Two Section) Rear Compartment Trim Panel Replacement (Two Section) Removal Procedure 1. Open the rear compartment. 2. Remove the rear compartment sill plate. Refer to Rear Compartment Sill Trim Plate Replacement (See: Rear Compartment Sill Trim Plate Replacement). 3. Remove the rear compartment convenience net and retainers, if equipped. Refer to Convenience Net Replacement - Rear Compartment (See: Convenience Net Replacement - Rear Compartment). 4. Remove the rear seat back. * For the non folding rear seat, refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)) in Seats. * For the folding rear seat, refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Lower Trim Panel Replacement > Page 11927 Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)) in Seats. 5. Remove the spare tire cover from the rear compartment. 6. Remove the push-in retainers from the rear compartment trim panel. 7. Pull back the rear compartment trim panel from the rear seating area. 8. Remove the rear compartment trim panel from the rear compartment. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Lower Trim Panel Replacement > Page 11928 1. Install the rear compartment trim panel to the rear compartment. 2. Pull back the rear compartment trim panel to the rear seating area. 3. Press the rear compartment trim over the rear shock tower studs. 4. Install the push-in retainers to the rear compartment trim panel. 5. Install the spare tire cover to the rear compartment. 6. Install the rear seat back. * For the non folding rear seat, refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)) in Seats. * For the folding rear seat, refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Lower Trim Panel Replacement > Page 11929 Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)) in Seats. 7. Install the rear compartment convenience net and retainers, if equipped. Refer to Convenience Net Replacement - Rear Compartment (See: Convenience Net Replacement - Rear Compartment). 8. Install the rear compartment sill plate. Refer to Rear Compartment Sill Trim Plate Replacement (See: Rear Compartment Sill Trim Plate Replacement). 9. Close the rear compartment. Rear Seat Back Body Panel Sound Barrier Replacement Rear Seat Back Body Panel Sound Barrier Replacement Removal Procedure 1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Seats/Seat Cushion/Service and Repair/Rear Seat Cushion Replacement) in Seats. 2. Remove the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)) in Seats. 3. Remove the rear quarter lower trim panel. Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Quarter Lower Rear Trim Panel Replacement)Quarter Lower Rear Trim Panel Replacement (Monte Carlo) (See: Quarter Lower Rear Trim Panel Replacement). 4. Remove the rear seat back sound barrier. Installation Procedure 1. Install rear seat back sound barrier. 2. Install the rear quarter trim panel. Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Quarter Lower Rear Trim Panel Replacement)Quarter Lower Rear Trim Panel Replacement (Monte Carlo) (See: Quarter Lower Rear Trim Panel Replacement). 3. Install the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)) in Seats. 4. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Seats/Seat Cushion/Service and Repair/Rear Seat Cushion Replacement) in Seats. Rear Window Shelf Trim Panel Replacement Rear Window Shelf Trim Panel Replacement (Impala) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Lower Trim Panel Replacement > Page 11930 Removal Procedure 1. If the vehicle is equipped with a folding rear seat back, perform the following steps: 1. Lower the seat backs. 2. Remove the upper bolts from the seat back frame. 2. If the vehicle is equipped with a fixed rear seat back, perform the following steps: 1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Seats/Seat Cushion/Service and Repair/Rear Seat Cushion Replacement) in Seats. 2. Remove the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)) in Seats. 3. Remove the rear upper quarter trim panel. Refer to Quarter Upper Trim Panel Replacement (Impala) (See: Quarter Upper Trim Panel Replacement). 4. Remove the push-in retainers from the front of the rear window trim panel. 5. Lift the rear window trim panel and remove the seat belts through the slots in the rear window trim panel. 6. Slide the rear window trim panel forward to disengage the integral hook from the retaining hole and remove the rear window trim panel. Installation Procedure 1. Slide the rear window trim panel rearward to engage the integral hook in the retaining hole. 2. Lift the rear window trim panel and route the seat belts through the slots in the rear window trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Lower Trim Panel Replacement > Page 11931 3. Install the push-in retainers to the front edge of the rear window trim panel. 4. Install the rear quarter upper trim panel. Refer to Quarter Upper Trim Panel Replacement (Impala) (See: Quarter Upper Trim Panel Replacement ). 5. If the vehicle is equipped with a fixed rear seat back, perform the following steps: 1. Install the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)) in Seats. 2. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Seats/Seat Cushion/Service and Repair/Rear Seat Cushion Replacement) in Seats. Notice: Refer to Fastener Notice in Cautions and Notices. 6. If the vehicle is equipped with a folding rear seat back, perform the following steps: 1. Install the upper bolts to the seat back frame. Tighten the bolts to 6 Nm (53 lb in) 2. Return the seat back to the original position. Windshield Pillar Garnish Molding Replacement Windshield Pillar Garnish Molding Replacement (Impala) Removal Procedure 1. Remove the windshield garnish molding from the clip retainers on the upper side rail. 2. Slide the roof leg of the garnish molding out from under the center pillar trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Lower Trim Panel Replacement > Page 11932 3. Remove the garnish molding from the windshield pillar. 4. Remove the garnish molding lower leg from the front door carpet retainer by pulling up and back. 5. Remove the windshield garnish molding. 6. If the clip retainer was damaged during the removal of the windshield garnish molding, remove the screw and the retainer from the upper side rail. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Lower Trim Panel Replacement > Page 11933 Notice: Refer to Fastener Notice in Cautions and Notices. 1. Install a new clip retainer to the upper side rail, if necessary. Tighten the retainer screw to 2 Nm (18 lb in). 2. Align the garnish molding lower leg to the front door carpet retainer and to the front door weatherstrip. 3. Align the garnish molding to the trough on the upper instrument panel trim panel. 4. Align the garnish molding retainers to the windshield pillar. 5. Slide the roof leg under the center pillar trim panel. 6. Align the garnish molding to the clip retainers on the upper side rail. 7. Install the garnish molding, applying pressure at all the retainers until fully seated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Locations > Component Locations Door Lock Cylinder: Component Locations Locations View Door Lock Cylinder Switch (RPO UA6 Only) Part of door lock actuator, rear edge of front door. RPO UA6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Locations > Component Locations > Page 11940 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Locations > Page 11941 Door Lock Cylinder: Service and Repair Door Lock Cylinder Replacement (Impala) Removal Procedure Important: Do not attempt repairs in order to correct lock cylinder discrepancies. Replace the lock cylinder. 1. Remove the front door outside handle. Refer to Front Side Door Outside Handle Replacement (Impala) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Handle/Front Door Exterior Handle/Service and Repair). 2. Remove the lock cylinder retainer clip. 3. Remove the lock cylinder from the front door outside door handle. Installation Procedure 1. Install the lock cylinder to the front door outside door handle. 2. Install the lock cylinder retainer clip. 3. Install the front door outside handle. Refer to Front Side Door Outside Handle Replacement (Impala) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Handle/Front Door Exterior Handle/Service and Repair). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 11946 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 11947 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 11948 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Component Locations Keyless Entry Receiver: Component Locations Locations View On the upper center of the instrument panel, next to the DRL ambient light sensor, under the defroster grille. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Component Locations > Page 11954 Keyless Entry Receiver: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Component Locations > Page 11955 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 11956 Remote Control Door Lock Receiver (RCDLR) Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 11957 Keyless Entry Receiver: Service and Repair Remote Control Door Lock Receiver Replacement REMOVAL PROCEDURE 1. Remove the defroster grille. 2. Disengage the remote control door lock receiver retainers. 3. Disconnect the remote control door lock receiver electrical connectors. 4. Remove the remote control door lock receiver. INSTALLATION PROCEDURE 1. Position the remote control door lock receiver to the upper instrument panel. Connect the remote control door lock receiver electrical connectors. 2. Engage the remote control door lock receiver retainers. 3. Install the defroster grille. 4. If a new remote control door lock receiver is being installed, synchronize the transmitter. Refer to Transmitter Synchronization. 5. If a new remote control door lock receiver is being installed, program the transmitter. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Transmitter Programming Keyless Entry Transmitter: Service and Repair Transmitter Programming In the event that a transmitter is lost, program the old and the new transmitters into the memory of the remote control door lock receiver. Up to 4 transmitters may be programmed. IMPORTANT: Once the keyless entry receiver enters the programming/diagnostic mode, the programming of the first transmitter erases all previous transmitter programming information. You must then program all of the transmitters. Program only 1 vehicle remote control door lock receiver at a time. If you program multiple receivers simultaneously, the same transmitter may possibly be programmed to more than 1 remote control door lock receiver. The following procedure describes how to program the remote control door lock transmitters to the remote control door lock receiver using the Tech 2. Perform the following steps: 1.Connect the scan tool to the following components: ^ An applicable power source ^ The vehicle data link connector (DLC) 2. Turn the ignition ON. 3. At the application menu screen, select F0 (body control module). 4. At the body control module screen, select F2 (special functions). 5. At the special functions menu screen, select F3 (program key fobs). 6. Follow the directions on the scan tool display in order to program the transmitters. 7. Press EXIT repeatedly until you view the application menu screen. 8. Disconnect the scan tool from the following components: ^ The accessory power port ^ The vehicle DLC 9. Validate that all the transmitters that were programmed operate properly. Refer to Keyless Entry System Operation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Transmitter Programming > Page 11962 Keyless Entry Transmitter: Service and Repair Transmitter Synchronization IMPORTANT: Loss of transmitter synchronization will occur when the following conditions are present: ^ The batteries on the keyless entry transmitter have been replaced. ^ A keyless entry transmitter has been activated many times when out of range of the vehicle's remote control door lock receiver. In order to resynchronize a transmitter, press and hold the transmitter LOCK and UNLOCK buttons simultaneously for at least 7 seconds. The horn will sound when the resynchronization is successful. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Component Locations Power Door Lock Actuator: Component Locations Door Lock, Front Side Rear edge of the front door. Door Lock, Rear (Actuator) Rear edge of the rear door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Component Locations > Page 11968 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > LF Door Lock Actuator, C2 LF Door Lock Actuator, C2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > LF Door Lock Actuator, C2 > Page 11971 LR Door Lock Actuator, C2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > LF Door Lock Actuator, C2 > Page 11972 RF Door Lock Actuator, C2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > LF Door Lock Actuator, C2 > Page 11973 RR Door Lock Actuator, C2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Procedures Power Door Lock Actuator: Procedures Lock Actuator Replacement - Front Door The front door lock actuator is part of the front door lock and cannot be serviced separately. Lock Actuator Replacement - Rear Door The rear door lock actuator is part of the rear door lock and cannot be serviced separately. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Procedures > Page 11976 Power Door Lock Actuator: Removal and Replacement Rear Side Door Lock Actuator Replacement (Impala) Removal Procedure 1. Remove the rear door lock. Refer to Rear Door Lock Replacement (Impala) (See: Door Locks/Service and Repair/Removal and Replacement/Rear Door Lock Replacement). 2. Remove the rear door lock to rear door lock actuator screws. 3. Remove the rear door actuator from the rear door lock. Installation Procedure 1. Align the rear door actuator to the rear door lock. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the rear door lock to rear door actuator screws. Tighten the rear door actuator screws to 2 Nm (18 lb in). 3. Install the rear door lock. Refer to Rear Door Lock Replacement (Impala) (See: Door Locks/Service and Repair/Removal and Replacement/Rear Door Lock Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Component Locations Power Door Lock Switch: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Component Locations > Page 11981 Locations View Center of the front door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Component Locations > Page 11982 Power Door Lock Switch: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Component Locations > Page 11983 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > LF Door Lock Switch LF Door Lock Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > LF Door Lock Switch > Page 11986 RF Door Lock Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Procedures Power Door Lock Switch: Procedures REMOVAL PROCEDURE 1. Remove the inside door handle bezel. 2. Remove the power door lock switch from the inside door handle bezel using a small, flat-bladed tool in order to release the retainers. 3. Disconnect the electrical connector from the power door lock switch. INSTALLATION PROCEDURE 1. Install the power door lock switch to the inside door handle bezel pressing into place until fully seated. 2. Connect the electrical connector to the power door lock switch. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 11989 3. Install the inside door handle bezel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 11990 Power Door Lock Switch: Removal and Replacement Door Lock Switch Replacement (Impala) Removal Procedure 1. Remove the inside door handle bezel. Refer to Door Inside Handle Bezel Replacement (Impala) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Door Inside Handle Bezel Replacement). 2. Remove the power door lock switch from the inside door handle bezel using a small, flat-bladed tool in order to release the retainers. 3. Disconnect the electrical connector from the power door lock switch. Installation Procedure 1. Install the power door lock switch to the inside door handle bezel pressing into place until fully seated. 2. Connect the electrical connector to the power door lock switch. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 11991 3. Install the inside door handle bezel. Refer to Door Inside Handle Bezel Replacement (Impala) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Door Inside Handle Bezel Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Locations > Page 11995 Trunk / Liftgate Lock Cylinder: Service and Repair Rear Compartment Lid Lock Cylinder Replacement (Impala) Removal Procedure 1. Remove the rear compartment lid applique. Refer to Rear Compartment Lid Applique Replacement (Impala) (). 2. Drill out the 2 rivets from the rear compartment lock cylinder. 3. Remove the rear compartment lock cylinder and gasket from the rear compartment lid. Installation Procedure 1. Align the lock cylinder shaft to the rear compartment lid latch. 2. Align the rear compartment lock cylinder and gasket to the holes in the rear compartment lid, and press in until fully seated. 3. Install the rear compartment lock cylinder and gasket to the rear compartment lid using 2 rivets. 4. Install the rear compartment lid applique. Refer to Rear Compartment Lid Applique Replacement (Impala) (). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Technical Service Bulletins > Mirrors - Heated Mirrors, Defrosting Time Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time INFORMATION Bulletin No.: 08-08-64-011A Date: February 25, 2010 Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories). Defrosting Time/Performance Concern The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM vehicles is slower to defrost than the passenger side outside rearview mirror. This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as the traditional glass on the passenger side mirror. The heating elements for the mirrors on both sides draw the same wattage, therefore the driver's side mirror will take approximately twice as long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function based upon this information prior to replacing the mirror. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair Power Mirror Motor: Service and Repair REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Disconnect the electrical connector to the mirror wire harness. CAUTION: Refer to Eye Protection Caution in Service Precautions. 3. Remove the mirror face. 4. Remove the screws from the mirror motor. 5. Pull the motor electrical harness through the mirror housing. 6. Remove the motor from the mirror housing. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair > Page 12004 1. Position the motor to the mirror housing. 2. Pull the motor electrical harness through to the inside door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws to the mirror motor. Tighten Tighten the mirror motor screws to 10 N.m (89 lb in). 4. Install the mirror face to the mirror housing. 5. Connect the electrical connector to the mirror wire harness. 6. Check the operation of the mirror. 7. Install the door trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Outside Rearview Mirror Remote Control Switch Power Mirror Switch: Locations Outside Rearview Mirror Remote Control Switch Front top of the driver's door panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Outside Rearview Mirror Remote Control Switch > Page 12009 Power Mirror Switch: Locations Outside Remote Control Rearview Mirror Switch Locations View Front top of the left front door panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 12010 Power Mirror Switch: Service and Repair REMOVAL PROCEDURE 1. Remove the front door pull cup from the front door inner trim panel. 2. Disconnect the electrical connectors from the power mirror switch. 3. Remove the power mirror switch from the front door pull cup, using a small flat-bladed tool at the side of the mirror switch in order to release the mirror control switch retainer. 4. Remove the power mirror switch from the front door pull cup. INSTALLATION PROCEDURE 1. Install the power mirror switch to the front door pull cup pressing into place until fully seated. 2. Connect the electrical connectors to the power mirror switch. 3. Install the front door pull cup to the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 12020 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 12026 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 12036 Paint: By Symptom Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 12037 Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 12038 TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 12039 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Technician Safety Information Paint: Technician Safety Information Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Technician Safety Information > Page 12042 Paint: Vehicle Damage Warnings Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Code Charts Paint: Application and ID Paint Code Charts Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Code Charts > Page 12045 Paint: Application and ID Paint Identification Precautions PAINT IDENTIFICATION Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important Always refer to the GM Approved Refinish Materials book GM PIN 4901 MD This book identities the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: 1. A cathodic immersion primer 2. A primer/surfacer 3. A basecoat 4. A clear top coat (clearcoat) Refer to the Service Parts ID Label to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Code Charts > Page 12046 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Code Charts > Page 12047 Paint: Application and ID Basecoat/Clearcoat Paint Systems Basecoat/Clearcoat Paint Systems Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Caution: Refer to Eye Protection Caution . All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers. If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clearcoat in an open panel. Always apply clearcoat to the next break point, body side molding, feature line, or the next panel. Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: * Lifting of primer coats caused by overly aggressive solvents in subsequent layers * Loss of adhesion between layers due to incompatibility of resin systems * Solvent popping or pinholing due to inappropriate solvent selection * Poor through-curing due to incompatible hardener resins or insufficient reactivity * Gloss reduction due to incompatible resins and/or solvents * Poor color accuracy due to pigment interactions with incompatible resins and/or solvents * Film defects, such as craters, blisters, orange peel loss of gloss, due to the use of inferior quality raw materials in incompatible products Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Code Charts > Page 12048 Paint: Application and ID Paint Identification Paint Identification Introduction Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important: Always refer to the GM Approved Refinish Materials book GM P/N 4901M-D that identifies the paint systems you may use. The Basecoat/clearcoat paint is factory applied in four layers: a cathodic immersion primer, a primer/surfacer, a basecoat, and a clear top coat (clearcoat) to give the finish a high gloss look. To identify the type of top coat used on the vehicle, you may refer to the Service Parts Identification Label. This label is located on the underside of the rear compartment lid. This label contains all paint related information for the vehicle, including: paint technology, paint codes, trim level, and any special order paint colors. Refer to Service Part Identification Label in General Information additional information on the Service Parts Identification Label. 1 - Vehicle Identification Number 2 - Engineering Model Number (Vehicle Division, Vehicle Line and Body Style) 3 - Interior Trim and Decor Level 4 - Exterior (Paint Color) WA Number 5 - Paint Technology 6 - Special Order Paint Colors and Numbers 7 - Vehicle Option Content Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Description and Operation Radiator Support: Description and Operation Radiator Support Description Radiator Support Assembly The radiator support can be serviced as a complete assembly. The radiator is made up of 5 major components: * Four upper * One lower Upper Radiator Support The upper radiator support is an assembly consisting of four components: * Two-piece upper tie bar * Left and Right engine compartment front panels Lower Radiator Support The lower radiator support is available as a separate replaceable component if necessary. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams Heated Seat Control Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Replacement Removal Procedure 1. Remove the front seat adjuster to floor pan bolts. 2. Tilt the seat forward. 3. Disconnect the electric connectors from the heated seat module. 4. Cut the tie straps to the module. 5. Remove the heated seat module. Installation Procedure 1. Position the heated seat module under the seat. 2. Connect the electric connectors to the heated seat module. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Page 12059 3. Install new tie straps to the module. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the front bucket seat adjuster-to-floor pan bolts. Tighten the front bucket seat adjuster-to-floor pan bolts to 42 Nm (31 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Locations Seat Heater Relay: Locations Below the seat. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Module: > 02-08-67-001 > Feb > 02 > Headliner - Sags At Sunroof Opening Sunroof / Moonroof Module: Customer Interest Headliner - Sags At Sunroof Opening File In Section: 08 - Body and Accessories Bulletin No.: 02-08-67-001 Date: February, 2002 TECHNICAL Subject: Headliner Sags At Sunroof Opening (Reattach Velcro(R) Strips) Models: 2000-2001 Chevrolet Impala Condition Some customers may comment that the headliner sags at the front of the sunroof opening. Cause The Velcro(R) strips may have come loose from the sunroof module and/or the headliner. Correction Replace the Velcro(R) strips that may have pulled loose from the sunroof module and/or the headliner. Clean the surface of the sunroof module using one of the cleaners listed below. Make sure the two halves of the Velcro(R) strips are properly aligned with each other before reattaching them. Apply adhesion promoter, P/N 12378462 (in Canada, us 10953554), to the sunroof module to improve the 3M(R) Dual Lock(TM) strip retention. If the Velcro(R) strips have come loose from the headliner, use hot melt glue to reattach them. Parts Information Parts are currently available from GMSPO. To obtain 3M(R) Dual Lock(TM) Mini-Pack, purchase it locally. Cleaning Solvents ^ 3M(R) General Purpose Adhesive Cleaner, P/N 08984 ^ Dominion Sure Seal, Sure Solve Stock BSS ^ Kent Acrosol Warranty Information For vehicles repaired under warranty use the table as shown. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Module: > 02-08-67-001 > Feb > 02 > Headliner - Sags At Sunroof Opening > Page 12071 DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Module: > 02-08-67-001 > Feb > 02 > Headliner - Sags At Sunroof Opening Sunroof / Moonroof Module: All Technical Service Bulletins Headliner - Sags At Sunroof Opening File In Section: 08 - Body and Accessories Bulletin No.: 02-08-67-001 Date: February, 2002 TECHNICAL Subject: Headliner Sags At Sunroof Opening (Reattach Velcro(R) Strips) Models: 2000-2001 Chevrolet Impala Condition Some customers may comment that the headliner sags at the front of the sunroof opening. Cause The Velcro(R) strips may have come loose from the sunroof module and/or the headliner. Correction Replace the Velcro(R) strips that may have pulled loose from the sunroof module and/or the headliner. Clean the surface of the sunroof module using one of the cleaners listed below. Make sure the two halves of the Velcro(R) strips are properly aligned with each other before reattaching them. Apply adhesion promoter, P/N 12378462 (in Canada, us 10953554), to the sunroof module to improve the 3M(R) Dual Lock(TM) strip retention. If the Velcro(R) strips have come loose from the headliner, use hot melt glue to reattach them. Parts Information Parts are currently available from GMSPO. To obtain 3M(R) Dual Lock(TM) Mini-Pack, purchase it locally. Cleaning Solvents ^ 3M(R) General Purpose Adhesive Cleaner, P/N 08984 ^ Dominion Sure Seal, Sure Solve Stock BSS ^ Kent Acrosol Warranty Information For vehicles repaired under warranty use the table as shown. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Module: > 02-08-67-001 > Feb > 02 > Headliner - Sags At Sunroof Opening > Page 12077 DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Page 12078 Sunroof / Moonroof Module: Specifications Sunroof Module Bolts 10 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Component Locations Sunroof / Moonroof Module: Component Locations Sunroof Module Locations View In the center of the roof, underneath the headliner. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Component Locations > Page 12081 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Component Locations > Page 12082 Sunroof / Moonroof Module: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Component Locations > Page 12083 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions Sunroof / Moonroof Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12086 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12087 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12088 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12089 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12090 Sunroof / Moonroof Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12091 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12092 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12093 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12094 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12095 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12096 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12097 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12098 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12099 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12100 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12101 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12102 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12103 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12104 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12105 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12106 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12107 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12108 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12109 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12110 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12111 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12112 Sunroof / Moonroof Module: Connector Views Sunroof Module, C1 Sunroof Module, C2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12113 Sunroof / Moonroof Module: Electrical Diagrams Power Sunroof Schematics: Without Driver Information Center (DIC) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12114 Power Sunroof Schematics: With Driver Information Center (DIC) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Page 12115 Sunroof / Moonroof Module: Service and Repair REMOVAL PROCEDURE 1. Position the sunroof to the fully closed position. 2. Remove the headliner. 3. Remove the express module from the sunroof module by sidling the express module towards the center of the vehicle. 4. Remove the express module from the vehicle. 5. Disconnect the electrical connectors from the express module. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Page 12116 1. Position the express module to the sunroof module. 2. Connect the electrical connector to the express module. 3. Install the express module to the sunroof module by sliding the express module to the right, pressing into place until fully locked in position. 4. Check the sunroof for proper operation. 5. Install the headliner. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trunk / Liftgate Relay > Component Information > Locations > Rear Compartment Lid Lamp Relay Trunk / Liftgate Relay: Locations Rear Compartment Lid Lamp Relay Inside the top underhood accessory wiring junction block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Specifications Luggage Rack: Specifications Fastener Tightening Specifications Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Locations > Sunshade (LH, RH) Sun Shade: Locations Sunshade (LH, RH) Side of the windshield header. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Locations > Sunshade (LH, RH) > Page 12130 Sun Shade: Locations Sunshade Illuminated Mirror Side of the windshield header. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Diagrams > Sunshade Mirror Lamp, LH Sunshade Mirror Lamp, LH Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Diagrams > Sunshade Mirror Lamp, LH > Page 12133 Sunshade Mirror Lamp, RH Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Procedures Sun Shade: Procedures Sunshade Panel Replacement REMOVAL PROCEDURE 1. Remove the sunroof glass panel. 2. Use a flat-bladed tool to push the sunshade slide blocks into the sunshade to release them from the sunroof guide assembly on one side of the sunshade. Hold the slide blocks in the released position and lift that side of the sunshade up. 3. Remove the sunshade panel through the roof opening. INSTALLATION PROCEDURE 1. Install the sunshade panel through the roof opening. 2. Insert the slide blocks on the right side of the sunshade into the sunroof guide assembly. 3. Push the sunshade slide locks on the left side of the sunshade into the sunshade to allow the sunshade to drop into position. Once the sunshade is in position, engage slide blocks into the left guide assembly. 4. Slide the sunshade forward and backward to check for smooth operation. 5. Install the sunroof glass panel. Sunshade Stop Replacement REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Procedures > Page 12136 1. Remove the headliner. 2. Remove the sunshade stop screw from the sunshade track. 3. To remove the sunshade stop, press the sunshade stop locking tab in and slide sunshade stop out of the sunshade track. INSTALLATION PROCEDURE 1. Position the sunshade stop to the sunshade track. 2. Press the sunshade stop into the sunshade track until fully seated. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the sunshade stop screw to the sunshade track. Tighten Tighten the sunshade stop screw to 2 N.m (18 lb in). 4. Install the headliner. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Procedures > Page 12137 Sun Shade: Removal and Replacement Sunroof Sunshade Replacement (First Design) Sunroof Sunshade Replacement (First Design) Removal Procedure 1. Remove the sunroof glass panel. Refer to Sunroof Glass Panel Replacement. 2. Position the sunshade to the closed position. 3. Remove the rear half of the sunshade by bowing the sunshade in the center and pushing the sunshade to 1 side in order to allow the opposite side of the sunshade to be lifted out of the sunshade channel. 4. Remove the rear half of the sunshade from the sunroof module. 5. Position the front half of the sunshade rearward. 6. Remove the front half of the sunshade by bowing the sunshade in the center then pushing the sunshade to 1 side in order to allow the opposite side of the sunshade to be lifted out of the sunshade channel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Procedures > Page 12138 7. Remove the front half of the sunshade from the sunroof module. Installation Procedure 1. Position the front sunshade to the sunroof module. 2. Insert 1 side of the front sunshade into the sunshade channel. 3. Bow the center of the front sunshade upwards in order to allow the opposite side to drop into the sunshade channel. 4. Slide the front sunshade forward. 5. Insert one side of the rear sunshade into the sunshade channel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Procedures > Page 12139 6. Position the tab on the rear sunshade to the center recessed area of the front sunshade and into the sunshade channel 7. Bow the center of the rear sunshade upwards in order to allow the opposite side to drop into the sunshade channel. 8. Inspect the sunshade for proper operation. 9. Install the sunroof window. Refer to Sunroof Glass Panel Replacement. Sunroof Sunshade Replacement (Second Design) Sunroof Sunshade Replacement (Second Design) Removal Procedure 1. Remove the sunroof glass panel. Refer to Sunroof Glass Panel Replacement. 2. Use a flat-bladed tool to push the sunshade slide blocks into the sunshade to release them from the sunroof guide assembly on one side of the sunshade. Hold the slide blocks in the released position and lift that side of the sunshade up. 3. Remove the sunshade panel through the roof opening. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Procedures > Page 12140 1. Install the sunshade panel through the roof opening. 2. Insert the slide blocks on the right side of the sunshade into the sunroof guide assembly. 3. Push the sunshade slide locks on the left side of the sunshade into the sunshade to allow the sunshade to drop into position. Once the sunshade is in position, engage slide blocks into the left guide assembly. 4. Slide the sunshade forward and backward to check for smooth operation. 5. Install the sunroof glass panel. Refer to Sunroof Glass Panel Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Limit Switch > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Limit Switch > Component Information > Diagrams > Sunroof Limit Switch, C5 Sunroof Limit Switch, C5 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Limit Switch > Component Information > Diagrams > Sunroof Limit Switch, C5 > Page 12146 Sunroof Limit Switch, C4 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Component Locations > Page 12151 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Page 12152 Sunroof Actuator Motor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations Sunroof / Moonroof Switch: Locations Center of the windshield header. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions Sunroof / Moonroof Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12158 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12159 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12160 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12161 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12162 Sunroof / Moonroof Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12163 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12164 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12165 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12166 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12167 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12168 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12169 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12170 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12171 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12172 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12173 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12174 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12175 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12176 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12177 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12178 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12179 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12180 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12181 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12182 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12183 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12184 Sunroof / Moonroof Switch: Electrical Diagrams Power Sunroof Schematics: Without Driver Information Center (DIC) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12185 Power Sunroof Schematics: With Driver Information Center (DIC) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Switch Replacement - Sunroof Position Encoding System Sunroof / Moonroof Switch: Service and Repair Switch Replacement - Sunroof Position Encoding System TOOLS REQUIRED J 41718 Sunroof Timing Pins REMOVAL PROCEDURE IMPORTANT: ^ The sunroof Positioning Encoding Switch (PES) (3) is aligned to the drive cables. The YES switch comes from the factory set to the glass panel CLOSED position. A position lock pin (1) has been installed on the top of the YES switch. The pin (1) must remain until after the installation of the actuator and of the YES switch. The pin locks the drive gears in place and must be removed before operation of the sunroof module. ^ If you reuse a YES switch, place the sunroof glass panel in the CLOSED position. Install the sunroof timing pins J41718. Install a position lock pin, or install 2 wires, such as the ends of a paper clip, then remove the YES switch from the sunroof module. The YES switch timing will be lost if you do not follow this procedure. 1. Position the sunroof glass panel to the closed position. 2. Remove the sunroof module from the vehicle. IMPORTANT: Before removing the YES switch from the sunroof module, the J 41718 sunroof timing pins must be installed to lock the cable/cam mechanism into position. 3. The cable/cam mechanisms on both sides of the glass contain a set of timing holes. These holes are aligned to the sunroof glass panel in the CLOSED position. Remove the left and right side front sunroof glass panel screws. Use a flat-bladed tool to push the cable/cam mechanisms forward or rearward to align with the holes. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Switch Replacement - Sunroof Position Encoding System > Page 12188 Install the J41718 sunroof timing pins into the left and right sunroof glass panel screw holes. Install the position lock pin or install 2 wires, such as the ends of a paper clip, to the YES switch before removal of the switch. 4. Remove the sunroof actuator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Switch Replacement - Sunroof Position Encoding System > Page 12189 Sunroof / Moonroof Switch: Service and Repair Power Sunroof Switch Replacement (W/O Overhead Console) REMOVAL PROCEDURE 1. Grasp the power sunroof switch on the left and right sides. IMPORTANT: The switch must be rotated, pulled down on the left side, to be removed. 2. Use 2, small, flat-bladed tools in order to disengage the clips which are located at the front and rear of the power sunroof switch. Hold the flat-bladed tools parallel to the roof and push straight in. 3. Rotate the power sunroof switch toward the left side to disengage it from the mounting bracket and pull down. 4. Disconnect the electrical connector from the power sunroof switch. 5. Remove the power sunroof switch from the vehicle. INSTALLATION PROCEDURE 1. Connect the electrical connector to the power sunroof switch. 2. Rotate the power sunroof switch back into the vehicle. 3. Firmly push the power sunroof switch into the headliner until fully seated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Switch Replacement - Sunroof Position Encoding System > Page 12190 Sunroof / Moonroof Switch: Service and Repair Power Sunroof Switch Replacement (With Overhead Console) REMOVAL PROCEDURE IMPORTANT: The driver information center control module, and the power sunroof switch is serviced as a complete part. 1. Remove the overhead console. 2. Remove the driver information center control module, containing the power sunroof switch from the overhead console. INSTALLATION PROCEDURE 1. Install the driver information center control module, containing the power sunroof switch to the overhead console. 2. Install the overhead console. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures Sunroof / Moonroof Drain: Procedures Sunroof Drain Channel Inspection and Cleaning DRAIN HOSE ROUTING A drain trough encircles the sunroof glass panel and water is drained off by the drain hoses located at each corner of the housing. A drain channel spans across the sunroof module at the rear of the glass panel and directs water into the trough. 1. Check to ensure the front drain hoses are routed down the windshield pillars and out the center of the pillar between the door hinges. Make sure the hoses are not kinked. Replace any torn or cracked hose. Refer to Sunroof Drain Hose Replacement - Front (Impala) or Sunroof Drain Hose Replacement - Front (Monte Carlo). 2. Check to ensure the rear drain hoses are routed through the rear pillars and out of the rocker panel. Make sure the rear hoses are properly routed in the metal roof slot and taped in place. Replace any torn or cracked hose. Refer to Sunroof Drain Hose Replacement - Rear (Impala) or Sunroof Drain Hose Replacement - Rear (Monte Carlo). PLUGGED DRAIN HOSE If a waterleak has occurred check for a plugged drain hose at each corner of drainage system. 1. Open the sunroof window. 2. To test for blockage, pour a small container of water into the module housing drain trough. Check each corner to confirm the drain hose is draining water. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 3. Use compressed air, 241 kPa (35 psi) or less to blow out any drain hose that is plugged. 4. Test the system again. 5. If the hose remains plugged, check to see it is properly routed and does not have a kink. Refer to Drain Hose Routing. 6. Remove any hoses that remain plugged. ^ For front hoses, refer to Sunroof Drain Hose Replacement - Front (Impala) or Sunroof Drain Hose Replacement - Front (Monte Carlo). ^ For rear hoses, refer to Sunroof Drain Hose Replacement - Rear (Impala) or Sunroof Drain Hose Replacement - Rear (Monte Carlo). 7. Remove the blockage using the following steps. 7.1. Push mechanics wire through the hose to remove the obstruction. 7.2. Use compressed air in order to blow out any remaining material. 7.3. Reinstall the hose. DISCONNECTED DRAIN HOSE Inspect the drainage system for disconnected drain hoses. Complete the following steps in order to obtain partial access to drain hoses and check for a disconnected hose. 1. Open the sunroof glass panel. 2. Lower the headliner as needed. For Impala refer to Headliner Replacement (Impala) or Headliner Replacement (Monte Carlo) in Interior Trim. 3. Connect any disconnected hoses. 4. Ensure that the rear drain hoses are properly routed in the metal roof slot and taped in place. Sunroof Drain Hose Replacement - Front REMOVAL PROCEDURE 1. Remove the front carpet retainer. 2. Remove the headliner. 3. Reposition the carpet in order to gain access to the access hole in the front pillar. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 12195 4. Disconnect the front sunroof drain hose from the sunroof module front spigot 5. Tie a string to the hose at the module end of the front sunroof drain hose. 6. Remove the grommet at the end of the front sunroof drain hose from the hole in the front pillar. 7. Remove the front sunroof drain hose from the front pillar, by pulling the hose from the access hole in the front pillar, allowing the string to remain in the pillar. INSTALLATION PROCEDURE 1. Tie the string to the hose at the front sunroof drain hose by the sunroof module. 2. Install the front sunroof drain hose, by pulling the string from the front pillar access hole and routing the front sunroof drain hose through the front pillar. 3. Remove the string from the front sunroof drain hose. 4. Install the end of the front sunroof drain hose to the grommet in the hole in the front pillar. 5. Connect the front sunroof drain hose to the sunroof module front spigot. 6. Inspect the front sunroof drain hose for proper installation. 7. Position the carpet back in place. 8. Install the front carpet retainer. 9. Install the headliner. Sunroof Drain Hose Replacement - Rear REMOVAL PROCEDURE 1. Remove the headliner. 2. Remove the rear quarter lower trim panel. 3. Disconnect the rear sunroof drain hose from the sunroof module rear spigot. 4. Remove the tape from the rear sunroof drain hose tube. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 12196 5. Disconnect the rear sunroof drain hose from the rear sunroof drain hose tube. 6. Remove the rear sunroof drain hose tube from the upper retainer clip. 7. Remove the rear sunroof drain hose from the rear pillar. INSTALLATION PROCEDURE 1. Position the rear sunroof drain hose to the rear pillar. 2. Route the rear sunroof drain hose (1) to the lower access hole in the quarter inner panel. 3. Install the rear sunroof drain hose tube to the upper retainer clip. 4. Route the rear sunroof drain hose to the outboard edge of the rear pillar and secure with tape. 5. Connect the rear sunroof drain hose to the sunroof module rear drain tube. 6. Connect the rear sunroof drain hose (1) to the rear sunroof drain hose tube. 7. Install the rear quarter lower trim panel. 8. Install the headliner. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 12197 Sunroof / Moonroof Drain: Removal and Replacement Sunroof Drain Hose Replacement (Rear) Sunroof Drain Hose Replacement (Impala Rear) Removal Procedure 1. Remove the rear seat seatback. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)) in Seats. 2. Remove the rear quarter upper trim. Refer to Quarter Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Upper Trim Panel Replacement) in Interior Trim. 3. Remove the rear quarter lower trim. Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Lower Rear Trim Panel Replacement) in Interior Trim. 4. Remove the headliner. Refer to Headlining Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Headliner/Service and Repair/Removal and Replacement) in Interior Trim. 5. Disconnect the rear sunroof drain hose from the sunroof module rear spigot. 6. Remove the tape from the rear sunroof drain hose tube (3 locations). 7. Disconnect the rear sunroof drain hose from the rear sunroof drain hose tube. 8. Remove the rear sunroof drain hose tube from the upper retainer clip. 9. Remove the rear sunroof drain hose from the rear pillar. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 12198 1. Position the rear sunroof drain hose to the rear pillar. 2. Route the rear sunroof drain hose to the lower access hole in the quarter inner panel. 3. Install the rear sunroof drain hose tube to the upper retainer clip. 4. Route the rear sunroof drain hose to the outboard edge of the rear pillar and secure with tape (3 locations). Important: Lube the inside of each end of the sunroof drain hose with general purpose lubricant GM P/N 12345579 or equivalent to aid in installation to the drain tubes. 5. Connect the rear sunroof drain hose to the sunroof module rear drain tube. 6. Connect the rear sunroof drain hose to the rear sunroof drain hose tube. 7. Install the headliner. Refer to Headlining Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Headliner/Service and Repair/Removal and Replacement) in Interior Trim. 8. Install the rear lower quarter trim. Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Lower Rear Trim Panel Replacement) in Interior Trim. 9. Install the rear quarter upper trim. Refer to Quarter Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Upper Trim Panel Replacement) in Interior Trim. 10. Install the rear seat seatback. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seats/Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)) in Seats. Sunroof Drain Hose Replacement (Front) Sunroof Drain Hose Replacement (Impala Front) Removal Procedure 1. Remove the front carpet retainer. Refer to Front Side Door Opening Floor Carpet Retainer Replacement (See: Interior Moulding / Trim/Carpet/Service and Repair/Front Side Door Opening Floor Carpet Retainer Replacement) in Interior Trim. 2. Remove the headliner. Refer to Headlining Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Headliner/Service and Repair/Removal and Replacement) in Interior Trim. 3. Reposition the carpet in order to gain access to the access hole in the front pillar. 4. Disconnect the front sunroof drain hose from the sunroof module front spigot. 5. Tie a string to the hose at the module end of the front sunroof drain hose. 6. Remove the grommet at the end of the front sunroof drain hose from the hole in the front pillar. 7. Remove the front sunroof drain hose from the front pillar, by pulling the hose from the access hole in the front pillar, allowing the string to remain in the pillar. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 12199 1. Tie the string to the hose at the front sunroof drain hose by the sunroof module. 2. Install the front sunroof drain hose, by pulling the string from the front pillar access hole and routing the front sunroof drain hose through the front pillar. 3. Remove the string from the front sunroof drain hose. 4. Install the end of the front sunroof drain hose to the grommet in the hole in the front pillar. 5. Connect the front sunroof drain hose to the sunroof module front spigot. 6. Inspect the front sunroof drain hose for proper installation. 7. Position the carpet back in place. 8. Install the front carpet retainer. Refer to Front Side Door Opening Floor Carpet Retainer Replacement (See: Interior Moulding / Trim/Carpet/Service and Repair/Front Side Door Opening Floor Carpet Retainer Replacement) in Interior Trim. 9. Install the headliner. Refer to Headlining Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Headliner/Service and Repair/Removal and Replacement in Interior Trim. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Module: > 02-08-67-001 > Feb > 02 > Headliner - Sags At Sunroof Opening Sunroof / Moonroof Module: Customer Interest Headliner - Sags At Sunroof Opening File In Section: 08 - Body and Accessories Bulletin No.: 02-08-67-001 Date: February, 2002 TECHNICAL Subject: Headliner Sags At Sunroof Opening (Reattach Velcro(R) Strips) Models: 2000-2001 Chevrolet Impala Condition Some customers may comment that the headliner sags at the front of the sunroof opening. Cause The Velcro(R) strips may have come loose from the sunroof module and/or the headliner. Correction Replace the Velcro(R) strips that may have pulled loose from the sunroof module and/or the headliner. Clean the surface of the sunroof module using one of the cleaners listed below. Make sure the two halves of the Velcro(R) strips are properly aligned with each other before reattaching them. Apply adhesion promoter, P/N 12378462 (in Canada, us 10953554), to the sunroof module to improve the 3M(R) Dual Lock(TM) strip retention. If the Velcro(R) strips have come loose from the headliner, use hot melt glue to reattach them. Parts Information Parts are currently available from GMSPO. To obtain 3M(R) Dual Lock(TM) Mini-Pack, purchase it locally. Cleaning Solvents ^ 3M(R) General Purpose Adhesive Cleaner, P/N 08984 ^ Dominion Sure Seal, Sure Solve Stock BSS ^ Kent Acrosol Warranty Information For vehicles repaired under warranty use the table as shown. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Module: > 02-08-67-001 > Feb > 02 > Headliner - Sags At Sunroof Opening > Page 12208 DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Module: > 02-08-67-001 > Feb > 02 > Headliner - Sags At Sunroof Opening Sunroof / Moonroof Module: All Technical Service Bulletins Headliner - Sags At Sunroof Opening File In Section: 08 - Body and Accessories Bulletin No.: 02-08-67-001 Date: February, 2002 TECHNICAL Subject: Headliner Sags At Sunroof Opening (Reattach Velcro(R) Strips) Models: 2000-2001 Chevrolet Impala Condition Some customers may comment that the headliner sags at the front of the sunroof opening. Cause The Velcro(R) strips may have come loose from the sunroof module and/or the headliner. Correction Replace the Velcro(R) strips that may have pulled loose from the sunroof module and/or the headliner. Clean the surface of the sunroof module using one of the cleaners listed below. Make sure the two halves of the Velcro(R) strips are properly aligned with each other before reattaching them. Apply adhesion promoter, P/N 12378462 (in Canada, us 10953554), to the sunroof module to improve the 3M(R) Dual Lock(TM) strip retention. If the Velcro(R) strips have come loose from the headliner, use hot melt glue to reattach them. Parts Information Parts are currently available from GMSPO. To obtain 3M(R) Dual Lock(TM) Mini-Pack, purchase it locally. Cleaning Solvents ^ 3M(R) General Purpose Adhesive Cleaner, P/N 08984 ^ Dominion Sure Seal, Sure Solve Stock BSS ^ Kent Acrosol Warranty Information For vehicles repaired under warranty use the table as shown. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Module: > 02-08-67-001 > Feb > 02 > Headliner - Sags At Sunroof Opening > Page 12214 DISCLAIMER Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Page 12215 Sunroof / Moonroof Module: Specifications Sunroof Module Bolts 10 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Component Locations Sunroof / Moonroof Module: Component Locations Sunroof Module Locations View In the center of the roof, underneath the headliner. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Component Locations > Page 12218 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Component Locations > Page 12219 Sunroof / Moonroof Module: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Component Locations > Page 12220 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions Sunroof / Moonroof Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12223 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12224 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12225 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12226 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12227 Sunroof / Moonroof Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12228 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12229 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12230 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12231 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12232 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12233 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12234 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12235 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12236 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12237 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12238 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12239 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12240 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12241 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12242 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12243 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12244 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12245 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12246 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12247 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12248 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12249 Sunroof / Moonroof Module: Connector Views Sunroof Module, C1 Sunroof Module, C2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12250 Sunroof / Moonroof Module: Electrical Diagrams Power Sunroof Schematics: Without Driver Information Center (DIC) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12251 Power Sunroof Schematics: With Driver Information Center (DIC) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Page 12252 Sunroof / Moonroof Module: Service and Repair REMOVAL PROCEDURE 1. Position the sunroof to the fully closed position. 2. Remove the headliner. 3. Remove the express module from the sunroof module by sidling the express module towards the center of the vehicle. 4. Remove the express module from the vehicle. 5. Disconnect the electrical connectors from the express module. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Page 12253 1. Position the express module to the sunroof module. 2. Connect the electrical connector to the express module. 3. Install the express module to the sunroof module by sliding the express module to the right, pressing into place until fully locked in position. 4. Check the sunroof for proper operation. 5. Install the headliner. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Sunroof Glass Height and Opening Fit Adjustment Sunroof / Moonroof Panel: Service and Repair Sunroof Glass Height and Opening Fit Adjustment 1. Slide the sunroof sunshade to the open position. 2. Move the sunroof glass panel to the fully closed position. 3. Loosen the sunroof glass panel screws. 4. Individually adjust the 4 corners (1) of the sunroof glass panel. 5. Adjust the front of the sunroof glass panel to 0.5 mm (0.020 in) below the top surface of the roof panel (3). 6. Adjust the rear of the sunroof glass panel to 0.5 mm (0.020 in) above the top surface of the roof panel (2). NOTE: Refer to Fastener Notice in Service Precautions. 7. Tighten the sunroof glass panel screws. Tighten Tighten the screws to 4 N.m (35 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Sunroof Glass Height and Opening Fit Adjustment > Page 12258 Sunroof / Moonroof Panel: Service and Repair Sunshade Glass Panel Replacement REMOVAL PROCEDURE 1. Position the sunroof sunshade to the full rearward position. 2. Remove the screws from the sunroof glass panel. 3. Lift the sunroof glass panel from the sunroof module to remove it. INSTALLATION PROCEDURE IMPORTANT: Ensure that the information logo stencil on the sunroof glass panel is at the rear of the opening. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Sunroof Glass Height and Opening Fit Adjustment > Page 12259 1. Position the sunroof glass panel into the sunroof module. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the sunroof glass panel screws. Tighten Tighten the sunroof glass panel screws to 4 N.m (35 lb in). 3. Adjust the sunroof glass panel. Refer to Sunroof Glass Height and Opening Fit Adjustment. 4. Inspect the sunroof glass panel for proper operation. 5. Reposition the sunroof sunshade to the original position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Finishing Lace Replacement Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Finishing Lace Replacement REMOVAL PROCEDURE 1. Beginning at the joint, pull the sunroof opening trim lace from the headliner. 2. Remove the sunroof opening trim lace from the headliner. INSTALLATION PROCEDURE 1. Beginning at the joint, install the sunroof opening trim lace into place around the sunroof opening. 2. Ensure the sunroof trim lace is fully seated to the headliner. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Finishing Lace Replacement > Page 12264 Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Glass Panel Seal Replacement REMOVAL PROCEDURE 1. Remove the sunroof glass panel. 2. Remove the sunroof glass seal from the sunroof glass panel frame by pulling the sunroof glass seal away at one point and continuing around the perimeter of the sunroof glass panel frame. 3. Wipe the perimeter of the sunroof glass panel frame area with a clean, dampened cloth using window cleaner GM P/N 1050427, Canadian P/N 992727, or isopropyl alcohol in order to clean the surface of the perimeter of the sunroof glass panel frame. Allow to air dry. INSTALLATION PROCEDURE 1. Position the sunroof glass panel seal onto the sunroof glass panel frame. IMPORTANT: Ensure that the sunroof glass seal is properly seated around the entire perimeter of the sunroof glass panel frame. 2. Firmly press the sunroof glass seal into place. A small rubber hammer will help in the installation. 3. Install the sunroof glass panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Wiring Harness > Component Information > Service and Repair Sunroof / Moonroof Wiring Harness: Service and Repair REMOVAL PROCEDURE IMPORTANT: Note the following locations: ^ The position of the wire harness routing ^ The location of the tie-straps that secure the harness to the drive cable tubes and the sunroof express module 1. Position the sunshade in the full forward position. 2. Remove the headliner. 3. Remove the rear shelf. 4. Cut the nylon tie straps on the express module and the drive cable tube. 5. Disconnect the electrical connector from the following components: ^ The sunroof express module ^ The sunroof actuator ^ The Position Encoding Switch 6. Remove the tape holding the wire harness to the module. 7. Remove the wire harness from the sunroof. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Wiring Harness > Component Information > Service and Repair > Page 12268 1. Position the wire harness to the sunroof. 2. Connect the electrical connectors to the following components: ^ The sunroof express module ^ The sunroof actuator ^ The Position Encoding Switch 3. Install new nylon tie straps to the express module and the drive cable tubes. 4. Install new tape to hold the wire harness to the module. 5. Check for proper operation of the sunroof. 6. Install the rear shelf. 7. Install the headliner. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Driver or Passenger Seat Head Restraint Replacement Head Rest: Service and Repair Driver or Passenger Seat Head Restraint Replacement Driver or Passenger Seat Head Restraint Replacement Removal Procedure 1. Raise the front seat head restraint to the full up position. 2. Press in the release tab (1) at the side of the head restraint retainer. 3. Remove the front seat head restraint from the front seat. Installation Procedure 1. Align the head restraint to the head restraint retainers in the front seat back. 2. Install the head restraint to the front seat, pressing down until fully seated. 3. Raise the head restraint to the full up position to ensure the head restraint stops at the detent. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Driver or Passenger Seat Head Restraint Replacement > Page 12274 4. Position the head restraint to its original position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Driver or Passenger Seat Head Restraint Replacement > Page 12275 Head Rest: Service and Repair Driver or Passenger Seat Head Restraint Retainer Replacement Driver or Passenger Seat Head Restraint Retainer Replacement Removal Procedure 1. Remove the head restraint from the front seat. Refer to Driver or Passenger Seat Head Restraint Replacement (See: Driver or Passenger Seat Head Restraint Replacement). 2. Position the front seat back to the full upright position. 3. Unhook the J-hook retainer at the bottom of the seat back cover. 4. Pull up on the front seat cover to enlarge the opening for access to the front seat frame. Important: The use of a small, flat-bladed tool as a lever under the top of the retainer will help in the removal of the head restraint retainer. 5. Reach carefully inside the front seat back between the seat back cover and the seat back pad and squeeze the bottom of the head restraint retainer together, while pulling the head restraint retainer upwards from the seat back frame. 6. Remove the head restraint retainer from the front seat back frame. Installation Procedure 1. Install the guide to the seat back frame, pressing in until fully seated into the front seat frame. 2. Reposition the front seat cover to the front seat back. 3. Close the J-hook retainer at the bottom edge of the front seat back cover. 4. Install the head restraint to the front seat. Refer to Driver or Passenger Seat Head Restraint Replacement (See: Driver or Passenger Seat Head Restraint Replacement). 5. Return the front seat back to the original position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams Heated Seat Control Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Driver Seat Adjuster Motor Assembly Power Seat Motor: Locations Driver Seat Adjuster Motor Assembly Below the driver's seat. Below the left front seat. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Seat Adjuster-Horizontal Actuator Motor, C1 Seat Adjuster-Horizontal Actuator Motor, C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Seat Adjuster-Horizontal Actuator Motor, C1 > Page 12289 Seat Adjuster-Rear Vertical Motor, C2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Seat Adjuster-Horizontal Actuator Motor, C1 > Page 12290 Seat Adjuster-Forward/Vertical Motor, C3 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Driver Seat Adjuster Switch Driver Seat Adjuster Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Driver Seat Adjuster Switch > Page 12295 Passenger Seat Adjuster Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 12296 Power Seat Switch: Service and Repair Power Seat Switch Replacement Removal Procedure 1. Remove the front seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). 2. Remove the power front seat switch from the front seat outer trim panel, using a small flat bladed tool. 3. Disconnect the electrical connector from the power front seat switch. 4. Remove the power front seat switch from the vehicle. Installation Procedure 1. Connect the electrical connector to the power front seat switch. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 12297 2. Install the power front seat switch to the front seat outer trim panel, pressing into place until fully seated. 3. Install the front seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Replacement (Split Bench) Seat Back: Service and Repair Front Seat Back Replacement (Split Bench) Front Seat Back Replacement (Split Bench) Removal Procedure 1. Remove the front seat from the vehicle. Refer to Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement). 2. Remove the front seat outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). 3. Remove the front seat armrest from the front seat. Refer to Front Seat Armrest Replacement (Impala) (See: Service and Repair/Front Seat Armrest Replacement). 4. Remove the front center seat belt buckle from the front seat. Refer to Front Seat Center Buckle Side Belt Replacement (Split Bench) . 5. Disconnect the J-hook retainers at each end of the front seat cushion and pull the front seat cushion cover open to expose the seat frame hinge. 6. Disconnect the J-hook retainers at the rear of the front seat cushion and pull open the front seat cushion cover to expose the seat frame hinge. 7. Remove the front seat back recliner roll pins from the seat back hinge. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Replacement (Split Bench) > Page 12302 8. Remove the front seat back bolts from the seat back hinge. 9. Lift up the front seat back and set it down on the front seat cushion. Important: Before removing cables and wire harness, make note of their position. 10. Pull out the lumbar cable, heated seat cable and the side air bag wire harness from the front seat cushion/frame area. 11. Disconnect the electrical connector for the heated seat, if equipped. 12. Remove the front seat back. Installation Procedure 1. Position the front seat back on the front seat cushion. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Replacement (Split Bench) > Page 12303 2. Route the lumbar cable, heated seat cable and the side air bag wire harness to the front seat cushion/frame area. 3. Connect the electrical connector for the heated seat, if equipped. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the front seat back bolts to the seat back hinge. Tighten the front seat back bolts to the seat back hinge to 25 Nm (18 lb ft). 5. Install new front seat back recliner roll pins to the seat back hinge. 6. Connect the J-hook retainers at the rear of the front seat cushion. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Replacement (Split Bench) > Page 12304 7. Connect the J-hook retainers at each end of the front seat cushion. 8. Install the front seat outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). 9. Install the front seat armrest to the front seat. Refer to Front Seat Armrest Replacement (Impala) (See: Service and Repair/Front Seat Armrest Replacement). 10. Install the front center seat belt buckle to the front seat. Refer to Front Seat Center Buckle Side Belt Replacement (Split Bench) . 11. Inspect the front seat back for proper operation. 12. Install the front seat into the vehicle. Refer to Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Replacement (Split Bench) > Page 12305 Seat Back: Service and Repair Rear Split Folding Seat Back Bolster Replacement Rear Split Folding Seat Back Bolster Replacement Removal Procedure 1. Remove the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)). 2. Remove the push-in J-hook retainers from both rear seat bolsters. 3. Pull back the trim on the right bolster in order to expose the rear compartment release handle cable, if equipped. 4. Reposition the compartment release handle cable from the right seat bolster, if equipped. 5. Pull back the seat bolster trim to expose the seat frame bolts. 6. Remove the bolts from the left and/or the right seat bolster. 7. Remove the left and/or the right seat bolster from the seat back frame. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Replacement (Split Bench) > Page 12306 8. Remove the push-in retainers from the center of the bolsters. 9. Remove the push-in tab from the end of the bolsters. 10. Remove the bolster trim covers from the bolsters pads. Installation Procedure 1. Install the rear seat bolster trim covers to the rear seat bolster pads. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Replacement (Split Bench) > Page 12307 2. Install the push-in retainers to the center of the bolsters, pressing into place until fully seated. 3. Reposition the trim cover side flap on the bolster under and over the side rail of the seat back frame. 4. Reposition the release handle cable to the right seat bolster, if equipped. Notice: Refer to Fastener Notice in Cautions and Notices. 5. Install the bolts to the left and/or the right seat bolsters. Tighten the bolster bolts to 6 Nm (53 lb in). 6. Install the push-in tab from the end of the bolsters, pressing into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Replacement (Split Bench) > Page 12308 7. Install the push-in J-hook retainers to the bolsters, pressing into place until fully seated. 8. Install the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Replacement (Split Bench) > Page 12309 Seat Back: Service and Repair Driver or Passenger Seat Back Cushion Frame Replacement Driver or Passenger Seat Back Cushion Frame Replacement Removal Procedure 1. Remove the front seat back. Refer to Front Seat Back Replacement (Bucket Seat) (See: Front Seat Back Replacement (Bucket Seat))Front Seat Back Replacement (Split Bench) (See: Front Seat Back Replacement (Split Bench)). 2. Remove the front seat back pad from the front seat back frame. Refer to Front Seat Back Cushion Pad Replacement (See: Seat Cushion/Service and Repair/Front Seat Back Cushion Pad Replacement). 3. Remove the inflatable restraint front side impact module, if equipped. Refer to Driver or Passenger Seat Side Inflatable Restraint Module Replacement in SIR. Installation Procedure 1. Install the inflatable restraint front side impact module, if equipped. Refer to Driver or Passenger Seat Side Inflatable Restraint Module Replacement in SIR. 2. Install the front seat back pad to the front seat back frame. Refer to Front Seat Back Cushion Pad Replacement (See: Seat Cushion/Service and Repair/Front Seat Back Cushion Pad Replacement). 3. Install the front seat back. Refer to Front Seat Back Replacement (Bucket Seat) (See: Front Seat Back Replacement (Bucket Seat))Front Seat Back Replacement (Split Bench) (See: Front Seat Back Replacement (Split Bench)). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Replacement (Split Bench) > Page 12310 Seat Back: Service and Repair Front Seat Back Replacement (Bucket Seat) Front Seat Back Replacement (Bucket Seat) Removal Procedure 1. Remove the front seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket). 2. Remove the front seat outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). 3. Disconnect the J-hook retainers at each end of the front seat cushion and pull the front seat cushion cover open to expose the seat frame hinge. 4. Disconnect the J-hook retainers at the rear of the front seat cushion and pull open the front seat cushion cover to expose the seat frame hinge. 5. Remove the front seat back recliner roll pins from the seat back hinge. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Replacement (Split Bench) > Page 12311 6. Remove the front seat back bolts from the seat back hinge. 7. Lift up the front seat back and set it down on the front seat cushion. Important: Before removing cables and wire harness, make note of their position. 8. Pull out the lumbar cable, heated seat cable and the side air bag wire harness from the front seat cushion frame area. 9. Remove the front seat back. Installation Procedure 1. Position the front seat back on the front seat cushion. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Replacement (Split Bench) > Page 12312 2. Route the lumbar cable, heated seat cable and the side air bag wire harness to the front seat cushion/frame area. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the front seat back bolts to the seat back hinge. Tighten the front seat back bolts to the seat back hinge to 25 Nm (18 lb ft). 4. Install new front seat back recliner roll pins to the seat back hinge. 5. Connect the J-hook retainers at the rear of the front seat cushion. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Replacement (Split Bench) > Page 12313 6. Connect the J-hook retainers at each end of the front seat cushion. 7. Install the front seat outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). 8. Inspect the front seat back for proper operation. 9. Install the front seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Replacement (Split Bench) > Page 12314 Seat Back: Service and Repair Rear Seat Back Cushion Frame Replacement (Rear Folding Seat) Rear Seat Back Cushion Frame Replacement (Rear Folding Seat) Removal Procedure 1. Remove the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)). 2. If fold down seat, remove the bolsters. Refer to Rear Split Folding Seat Back Bolster Replacement (See: Rear Split Folding Seat Back Bolster Replacement). 3. Remove the rear seat back pad. Refer to Rear Seat Back Cushion Pad Replacement (Non Folding) (See: Seat Cushion/Service and Repair/Rear Seat Back Cushion Pad Replacement (Non Folding))Rear Seat Back Cushion Pad Replacement (Folding) (See: Seat Cushion/Service and Repair/Rear Seat Back Cushion Pad Replacement (Folding)). 4. Remove the seat back pad frame. Installation Procedure 1. Install the seat back frame. 2. If fold down seat, install the bolsters. Refer to Rear Split Folding Seat Back Bolster Replacement (See: Rear Split Folding Seat Back Bolster Replacement). 3. Install the rear seat back pad. Refer to Rear Seat Back Cushion Pad Replacement (Non Folding) (See: Seat Cushion/Service and Repair/Rear Seat Back Cushion Pad Replacement (Non Folding))Rear Seat Back Cushion Pad Replacement (Folding) (See: Seat Cushion/Service and Repair/Rear Seat Back Cushion Pad Replacement (Folding)). 4. Install the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 12319 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 12320 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 12321 Seat Cover: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 12322 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 12323 Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover Replacement Seat Cover: Service and Repair Driver or Passenger Seat Back Cushion Cover Replacement Driver or Passenger Seat Back Cushion Cover Replacement Removal Procedure Important: The left, front seat is equipped with a side impact air bag. This must be disabled before any work is done on this seat. 1. Disable the SIR system if the seat is equipped with an air bag. Refer to Disabling the SIR System in Restraints. 2. Remove the front seat head restraint. Refer to Driver or Passenger Seat Head Restraint Replacement (See: Head Rest/Service and Repair/Driver or Passenger Seat Head Restraint Replacement). Important: When removing the seat back bezel on the coupe, a replacement part should be available as the original part has a tendency to crack. 3. Use the following steps to remove the bezel from the seat back release lever, if coupe. * At the same time, slide a flat-bladed tool under each side of the bezel. * Rotate the tools out, away from the seat back then press in to free the bezel from its retainers. * Remove the bezel from the seat back. 4. Unfasten the J-hook retainers at the bottom of the seat back cover. 5. Remove the rear screw in the seat cushion trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). 6. Pull out the seat back cover end flaps (3 each side). 7. Remove the front seat head restraint retainers. Refer to Driver or Passenger Seat Head Restraint Retainer Replacement (See: Head Rest/Service and Repair/Driver or Passenger Seat Head Restraint Retainer Replacement). 8. Position the seat full up and full back and disconnect the SIR connector, if equipped. 9. Disconnect the electrical connector for the heated seat back, if equipped. 10. Position the seat full forward. 11. Remove the seat belt nut from the seat stud. For the left seat refer to Seat Belt Retractor Replacement - Left Front (Impala) Seat Belt Retractor Replacement - Left Front (Monte Carlo) and for the right refer to Seat Belt Retractor Replacement Right Front (Impala) Seat Belt Retractor Replacement - Right Front (Monte Carlo) . 12. Position the seat back full down. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover Replacement > Page 12326 13. Reach inside of the front seat back cover and unfasten the hook and the loop retainers securing the front seat back cover to the pad. 14. Position the seat back to the upright position. 15. Unfasten the seat back cover from the retainer at the side impact airbag using a small curved bladed tool first to gain access to the front seat back material. 16. Unfasten the seat back cover from the retainer at the side impact airbag, by pressing in and pulling down on the seat back cover. 17. Position the seat back full down. 18. Reach inside of the front seat back cover and unfasten the hook and the loop retainers securing the front seat back cover to the pad. 19. Position the seat back to the vertical position. 20. If the seat back is heated, pull the electrical harness for the seat back heater up though the seat cushion. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover Replacement > Page 12327 21. Remove the front seat back cover from the seat back, by pulling the seat back cover up and over the pad. Installation Procedure 1. Position the front seat back cover to the pad. 2. Pull the seat back cover over the pad and aline the hook and the loop retainers. 3. Use firm hand pressure in order to fasten the hook and the loop retainers, securing the front seat back cover to the pad. 4. Install the front seat head restraint retainers. Refer to Driver or Passenger Seat Head Restraint Retainer Replacement (See: Head Rest/Service and Repair/Driver or Passenger Seat Head Restraint Retainer Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover Replacement > Page 12328 5. If coupe, install the front seat back release knob bezel (1), pressing into place until fully seated. 6. Install the seat back cover to the retainer at the side impact airbag, by pressing in and pulling down on the seat back cover. 7. Install the seat back heater electrical line through the seat cushion. 8. Install the front seat back cover end flaps (3 each side). 9. Install the rear screw in the seat cushion trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). 10. Fasten the J-hook retainer at the bottom of the seat back cover. 11. Install the front seat head restraint. Refer to Driver or Passenger Seat Head Restraint Replacement (See: Head Rest/Service and Repair/Driver or Passenger Seat Head Restraint Replacement). 12. Connect the electrical connector for the heated seat back, if equipped. 13. Enable the SIR system if the seat is equipped with an air bag. Refer to Enabling the SIR System in Restraints. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover Replacement > Page 12329 Seat Cover: Service and Repair Front Seat Cushion Cover Replacement (Bucket Seat) Front Seat Cushion Cover Replacement (Bucket Seat) Removal Procedure 1. Remove the front seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket). 2. Remove the front seat back. Refer to Front Seat Back Replacement (Bucket Seat) (See: Seat Back/Service and Repair/Front Seat Back Replacement (Bucket Seat))Front Seat Back Replacement (Split Bench) (See: Seat Back/Service and Repair/Front Seat Back Replacement (Split Bench)). 3. Remove the front seat outer trim bracket. 4. Disconnect the electrical connector for the heated seat, if equipped. 5. Unfasten the J-hook retainers on all sides of the front seat cushion cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover Replacement > Page 12330 6. Remove the hog rings from the rear of the front seat cushion cover. 7. Unfasten the hook and the loop retainers securing the seat cushion cover to the cushion. 8. Remove the front seat cushion cover from the front seat cushion. 9. Remove the J-hook retainers from the front seat frame, if required. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover Replacement > Page 12331 1. Install the J-hook retainers to the front seat frame, if required. 2. Align the front seat cushion cover to the front seat cushion. 3. Install the seat cushion cover onto the front seat cushion. 4. Install the hog rings to the rear of the front seat cushion cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover Replacement > Page 12332 5. Fasten the J-hook retainers on all sides of the front seat cushion cover. 6. Fasten the hook and the loop retainers securing the seat cushion cover to the cushion, by pressing in place until fully seated. 7. Connect the electrical connector for the heated seat, if equipped. 8. Install the front seat outer trim bracket. 9. Install the front seat back. Refer to Front Seat Back Replacement (Bucket Seat) (See: Seat Back/Service and Repair/Front Seat Back Replacement (Bucket Seat))Front Seat Back Replacement (Split Bench) (See: Seat Back/Service and Repair/Front Seat Back Replacement (Split Bench)). 10. Install the front seat to the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover Replacement > Page 12333 Seat Cover: Service and Repair Front Seat Cushion Cover Replacement (Split Bench) Front Seat Cushion Cover Replacement (Split Bench) Removal Procedure 1. Remove the front seat from the vehicle. Refer to Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement). 2. Remove the front seat armrest from the front seat. Refer to Front Seat Armrest Replacement (Impala) (See: Service and Repair/Front Seat Armrest Replacement). 3. Remove the front seat back. Refer to Front Seat Back Replacement (Bucket Seat) (See: Seat Back/Service and Repair/Front Seat Back Replacement (Bucket Seat))Front Seat Back Replacement (Split Bench) (See: Seat Back/Service and Repair/Front Seat Back Replacement (Split Bench)). 4. Remove the front seat outer trim bracket. 5. Disconnect the electrical connector for the heated seat, if equipped. 6. Unfasten the J-hook retainers on all sides of the front seat cushion cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover Replacement > Page 12334 7. Unfasten the retainers from the seat frame on the bottom of the front seat cushion. 8. Unfasten the retainer from the front seat frame at the seat belt. 9. Remove the hog rings from the rear of the front seat cushion cover. 10. Unfasten the hook and the loop retainers securing the front seat cushion cover to the cushion. 11. Remove the front seat cushion cover from the front seat cushion. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover Replacement > Page 12335 12. Remove the J-hook retainers from the front seat frame, if required. Installation Procedure 1. Install the J-hook retainers to the front seat frame, if required. 2. Align the front seat cushion cover to the front seat cushion. 3. Install the front seat cushion cover onto the front seat cushion. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover Replacement > Page 12336 4. Install the hog rings to the rear of the front seat cushion cover. 5. Fasten the J-hook retainers on all sides of the front seat cushion cover. 6. Fasten the retainers to the front seat frame on the bottom of the front seat cushion. 7. Fasten the retainer to the front seat frame at the seat belt. 8. Fasten the hook and the loop retainers securing the front seat cushion cover to the cushion, by pressing in place until fully seated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover Replacement > Page 12337 9. Connect the electrical connector for the heated seat, if equipped. 10. Install the front seat outer trim bracket. 11. Install the front seat armrest from the front seat. Refer to Front Seat Armrest Replacement (Impala) (See: Service and Repair/Front Seat Armrest Replacement). 12. Install the front seat back. Refer to Front Seat Back Replacement (Bucket Seat) (See: Seat Back/Service and Repair/Front Seat Back Replacement (Bucket Seat))Front Seat Back Replacement (Split Bench) (See: Seat Back/Service and Repair/Front Seat Back Replacement (Split Bench)). 13. Install the front seat to the vehicle. Refer to Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover Replacement > Page 12338 Seat Cover: Service and Repair Rear Seat Back Cushion Cover Replacement (Non Folding) Rear Seat Back Cushion Cover Replacement (Non Folding) Removal Procedure 1. Remove the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)). 2. Remove the rear seat armrest, if equipped. Refer to Rear Seat Armrest Replacement (See: Service and Repair/Rear Seat Armrest Replacement). 3. Remove the hog rings from the rear seat back cover. 4. Reach inside of the rear seat back cover in order to unfasten the hook and the loop retainers securing the rear seat back cover to the pad. 5. Remove the rear seat back cover from the pad. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover Replacement > Page 12339 1. Position the rear seat back cover to the pad. 2. Align the alignment marks on the rear seat back cover to the alignment marks on the pad. 3. Pull the rear seat back cover over the pad while alining the hook and the loop retainers. 4. Pull the rear seat back cover over the pad and pull over and under the edge. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover Replacement > Page 12340 5. Use firm hand pressure in order to fasten the hook and the loop retainers, securing the rear seat back cover to the pad. 6. Align the alignment marks on the rear seat back cover to the alignment marks on the pad, on the back side. 7. Install the hog rings to the rear seat back cover. 8. Install the rear seat armrest, if equipped. Refer to Rear Seat Armrest Replacement (See: Service and Repair/Rear Seat Armrest Replacement). 9. Install the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover Replacement > Page 12341 Seat Cover: Service and Repair Rear Seat Back Cushion Cover Replacement (Folding) Rear Seat Back Cushion Cover Replacement (Folding) Removal Procedure 1. Remove the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)). 2. Remove the rear seat back bolsters. Refer to Rear Split Folding Seat Back Bolster Replacement (See: Seat Back/Service and Repair/Rear Split Folding Seat Back Bolster Replacement). 3. Remove the bolts from the rear split folding seat back frame. 4. Remove the left rear seat back from the rear seat back frame. 5. Remove the right rear seat back from the rear seat back frame. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover Replacement > Page 12342 6. Unhook the J-hook retainers at the bottom of the right and/or left rear seat back. 7. Pull back the right and/or left carpet in order to expose the rear seat trim flaps in order to remove the staples. 8. Reach inside of the right and/or left rear seat back cover in order to unfasten the hook and loop retainers securing the rear seat back cover to the pad. 9. Remove the rear seat folding armrest, if equipped. Refer to Rear Seat Armrest Replacement (See: Service and Repair/Rear Seat Armrest Replacement). 10. Remove the right and/or left rear seat back cover from the rear seat back, by pulling the rear seat back cover up and over the pad. Installation Procedure 1. Install the right and/or left rear seat back cover to the rear seat back, by pulling the rear seat back cover down and over the pad. 2. Reach inside of the right rear seat back cover and reposition the rear seat back release pullstrap through the rear seat back cover. 3. Aline the hook and the loop retainers. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover Replacement > Page 12343 4. Use firm hand pressure in order to fasten the hook and loop retainers, securing the rear seat back cover to the pad. 5. Install the rear seat folding armrest, if equipped. Refer to Rear Seat Armrest Replacement (See: Service and Repair/Rear Seat Armrest Replacement). 6. Reposition the rear seat back cable on the right rear seat back. 7. Reposition the rear seat trim flaps. 8. Install new staples to the rear seat trim flaps. 9. Fasten the J-hook retainer at the bottom of the right and/or left rear seat back. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover Replacement > Page 12344 10. Install the left rear seat back to the rear seat back frame. 11. Install the right rear seat back to the rear seat back frame. Notice: Refer to Fastener Notice in Cautions and Notices. 12. Install the split folding seat back frame bolts. Tighten the split folding seat back frame bolts to 10 Nm (89 lb in). 13. Install the rear seat back bolsters. Refer to Rear Split Folding Seat Back Bolster Replacement (See: Seat Back/Service and Repair/Rear Split Folding Seat Back Bolster Replacement). 14. Install the seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Seat Cushion/Service and Repair/Rear Seat Back Cushion Replacement (Folding)). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement Seat Cushion: Service and Repair Front Seat Back Cushion Pad Replacement Front Seat Back Cushion Pad Replacement Removal Procedure 1. Remove the front seat back cover. Refer to Driver or Passenger Seat Back Cushion Cover Replacement (See: Seat Cover/Service and Repair/Driver or Passenger Seat Back Cushion Cover Replacement). 2. Remove the hog rings securing the seat back pad to the frame. 3. Remove the front seat back pad from the seat frame. Installation Procedure 1. Install the front seat back pad to the seat frame. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12349 2. Install the hog rings securing the seat back pad to the frame. 3. Install the front seat back cover. Refer to Driver or Passenger Seat Back Cushion Cover Replacement (See: Seat Cover/Service and Repair/Driver or Passenger Seat Back Cushion Cover Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12350 Seat Cushion: Service and Repair Driver or Passenger Seat Cushion Frame Replacement Driver or Passenger Seat Cushion Frame Replacement Removal Procedure 1. Remove the front seat from the vehicle. Refer to the following procedures: * Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket) * Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement) 2. Remove the front seat back from the front seat. Refer to Front Seat Back Replacement (Bucket Seat) (See: Seat Back/Service and Repair/Front Seat Back Replacement (Bucket Seat))Front Seat Back Replacement (Split Bench) (See: Seat Back/Service and Repair/Front Seat Back Replacement (Split Bench)). 3. Remove the front seat cushion cover from the front seat cushion. Refer to Front Seat Cushion Cover Replacement (Bucket Seat) (See: Seat Cover/Service and Repair/Front Seat Cushion Cover Replacement (Bucket Seat))Front Seat Cushion Cover Replacement (Split Bench) (See: Seat Cover/Service and Repair/Front Seat Cushion Cover Replacement (Split Bench)). 4. Remove the front seat cushion from the front seat frame. Refer to Front Seat Cushion Replacement (See: Front Seat Cushion Replacement). 5. Remove the front seat recliner assembly from the front seat cushion frame. Refer to Driver or Passenger Seat Recliner Replacement (See: Service and Repair/Driver or Passenger Seat Recliner Replacement). 6. Remove the bolts from the front seat cushion frame to the front seat track adjusters. 7. Remove the front seat frame from the front seat track adjusters. 8. For split bench, remove the bolts from the front seat frame to the front seat track adjusters. 9. Remove the front seat cushion frame from the front seat track adjusters. Installation Procedure 1. Position the front seat cushion frame to the front seat adjusters. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12351 2. Install the bolts to the seat cushion frame to the front seat track adjusters. Notice: Refer to Fastener Notice in Cautions and Notices. 3. For split bench, install the bolts to the front seat frame to the front seat track adjusters. Tighten the bolts to the front seat frame to 25 Nm (18 lb ft). 4. Install the front seat recliner assembly to the front seat cushion frame. Refer to Driver or Passenger Seat Recliner Replacement (See: Service and Repair/Driver or Passenger Seat Recliner Replacement). 5. Install the front seat cushion to the front seat cushion frame. Refer to Front Seat Cushion Replacement (See: Front Seat Cushion Replacement). 6. Install the front seat cushion cover to the front seat cushion. Refer to Front Seat Cushion Cover Replacement (Bucket Seat) (See: Seat Cover/Service and Repair/Front Seat Cushion Cover Replacement (Bucket Seat))Front Seat Cushion Cover Replacement (Split Bench) (See: Seat Cover/Service and Repair/Front Seat Cushion Cover Replacement (Split Bench)). 7. Install the front seat back to the front seat. Refer to Front Seat Back Replacement (Bucket Seat) (See: Seat Back/Service and Repair/Front Seat Back Replacement (Bucket Seat))Front Seat Back Replacement (Split Bench) (See: Seat Back/Service and Repair/Front Seat Back Replacement (Split Bench)). 8. Install the front seat to the vehicle. Refer to the following procedures: * Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket) * Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12352 Seat Cushion: Service and Repair Rear Seat Back Cushion Pad Replacement (Non Folding) Rear Seat Back Cushion Pad Replacement (Non Folding) Removal Procedure 1. Remove the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Rear Seat Back Cushion Replacement (Folding)). 2. Remove the rear seat back cover from the rear seat back pad. Refer to Rear Seat Back Cushion Cover Replacement (Non Folding) (See: Seat Cover/Service and Repair/Rear Seat Back Cushion Cover Replacement (Non Folding))Rear Seat Back Cushion Cover Replacement (Folding) ( See: Seat Cover/Service and Repair/Rear Seat Back Cushion Cover Replacement (Folding)). 3. Remove the rear seat back pad from the seat back frame. Installation Procedure 1. Install the rear seat back pad on the seat back frame. 2. Install the rear seat back cover to the rear seat back pad. Refer to Rear Seat Back Cushion Cover Replacement (Non Folding) (See: Seat Cover/Service and Repair/Rear Seat Back Cushion Cover Replacement (Non Folding))Rear Seat Back Cushion Cover Replacement (Folding) ( See: Seat Cover/Service and Repair/Rear Seat Back Cushion Cover Replacement (Folding)). 3. Install the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Rear Seat Back Cushion Replacement (Folding)). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12353 Seat Cushion: Service and Repair Seat Cushion Outer Trim Panel Replacement Seat Cushion Outer Trim Panel Replacement Removal Procedure 1. Remove the front seat back recliner handle, using a small, flat-bladed tool. 2. Remove the front seat lumbar knob by pulling it off. 3. Remove the screw from the rear of the front seat cushion trim panel. 4. Use a small, flat-bladed tool to remove the push-in retainer from the front of the front seat cushion trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12354 5. Pull off the front seat cushion trim panel to release the two retaining clips located on each side the recliner handle hole. 6. Remove the power seat switch from the front seat cushion trim panel, if equipped. Refer to Power Seat Switch Replacement (See: Power Seat Switch/Service and Repair). 7. Remove the heated seat switch from the front seat cushion trim panel, if equipped. 8. Remove the lumbar control switch from the front seat cushion trim panel, if equipped. Refer to Lumbar Switch Replacement (See: Service and Repair/Lumbar Switch Replacement). 9. Remove the front seat cushion trim panel from the vehicle. Installation Procedure 1. Install the power seat switch to the front seat cushion trim panel, if equipped. Refer to Power Seat Switch Replacement (See: Power Seat Switch/Service and Repair). 2. Install the lumbar control switch to the front seat cushion trim panel, if equipped. 3. Install the heated seat switch to the front seat cushion trim panel, if equipped. 4. Install the seat cushion trim panel, pressing in until the two retaining clips are fully seated. Notice: Refer to Fastener Notice in Cautions and Notices. 5. Install the front cushion trim panel rear screws. Tighten the front seat cushion trim panel screws to 3 Nm (27 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12355 6. Install the push-in retainer to the front of the front seat cushion trim panel, pressing into place until fully seated. 7. Install the front seat lumbar knob, pressing into place until fully seated. 8. Install the front seat back recliner handle, pressing into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12356 Seat Cushion: Service and Repair Front Seat Back Cushion Pad Replacement Front Seat Back Cushion Pad Replacement Removal Procedure 1. Remove the front seat back cover. Refer to Driver or Passenger Seat Back Cushion Cover Replacement (See: Seat Cover/Service and Repair/Driver or Passenger Seat Back Cushion Cover Replacement). 2. Remove the hog rings securing the seat back pad to the frame. 3. Remove the front seat back pad from the seat frame. Installation Procedure 1. Install the front seat back pad to the seat frame. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12357 2. Install the hog rings securing the seat back pad to the frame. 3. Install the front seat back cover. Refer to Driver or Passenger Seat Back Cushion Cover Replacement (See: Seat Cover/Service and Repair/Driver or Passenger Seat Back Cushion Cover Replacement). Driver or Passenger Seat Cushion Frame Replacement Driver or Passenger Seat Cushion Frame Replacement Removal Procedure 1. Remove the front seat from the vehicle. Refer to the following procedures: * Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket) * Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement) 2. Remove the front seat back from the front seat. Refer to Front Seat Back Replacement (Bucket Seat) (See: Seat Back/Service and Repair/Front Seat Back Replacement (Bucket Seat))Front Seat Back Replacement (Split Bench) (See: Seat Back/Service and Repair/Front Seat Back Replacement (Split Bench)). 3. Remove the front seat cushion cover from the front seat cushion. Refer to Front Seat Cushion Cover Replacement (Bucket Seat) (See: Seat Cover/Service and Repair/Front Seat Cushion Cover Replacement (Bucket Seat))Front Seat Cushion Cover Replacement (Split Bench) (See: Seat Cover/Service and Repair/Front Seat Cushion Cover Replacement (Split Bench)). 4. Remove the front seat cushion from the front seat frame. Refer to Front Seat Cushion Replacement (See: Front Seat Cushion Replacement). 5. Remove the front seat recliner assembly from the front seat cushion frame. Refer to Driver or Passenger Seat Recliner Replacement (See: Service and Repair/Driver or Passenger Seat Recliner Replacement). 6. Remove the bolts from the front seat cushion frame to the front seat track adjusters. 7. Remove the front seat frame from the front seat track adjusters. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12358 8. For split bench, remove the bolts from the front seat frame to the front seat track adjusters. 9. Remove the front seat cushion frame from the front seat track adjusters. Installation Procedure 1. Position the front seat cushion frame to the front seat adjusters. 2. Install the bolts to the seat cushion frame to the front seat track adjusters. Notice: Refer to Fastener Notice in Cautions and Notices. 3. For split bench, install the bolts to the front seat frame to the front seat track adjusters. Tighten the bolts to the front seat frame to 25 Nm (18 lb ft). 4. Install the front seat recliner assembly to the front seat cushion frame. Refer to Driver or Passenger Seat Recliner Replacement (See: Service and Repair/Driver or Passenger Seat Recliner Replacement). 5. Install the front seat cushion to the front seat cushion frame. Refer to Front Seat Cushion Replacement (See: Front Seat Cushion Replacement). 6. Install the front seat cushion cover to the front seat cushion. Refer to Front Seat Cushion Cover Replacement (Bucket Seat) (See: Seat Cover/Service and Repair/Front Seat Cushion Cover Replacement (Bucket Seat))Front Seat Cushion Cover Replacement (Split Bench) (See: Seat Cover/Service and Repair/Front Seat Cushion Cover Replacement (Split Bench)). 7. Install the front seat back to the front seat. Refer to Front Seat Back Replacement (Bucket Seat) (See: Seat Back/Service and Repair/Front Seat Back Replacement (Bucket Seat))Front Seat Back Replacement (Split Bench) (See: Seat Back/Service and Repair/Front Seat Back Replacement (Split Bench)). 8. Install the front seat to the vehicle. Refer to the following procedures: * Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12359 * Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement) Rear Seat Back Cushion Pad Replacement (Non Folding) Rear Seat Back Cushion Pad Replacement (Non Folding) Removal Procedure 1. Remove the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Rear Seat Back Cushion Replacement (Folding)). 2. Remove the rear seat back cover from the rear seat back pad. Refer to Rear Seat Back Cushion Cover Replacement (Non Folding) (See: Seat Cover/Service and Repair/Rear Seat Back Cushion Cover Replacement (Non Folding))Rear Seat Back Cushion Cover Replacement (Folding) ( See: Seat Cover/Service and Repair/Rear Seat Back Cushion Cover Replacement (Folding)). 3. Remove the rear seat back pad from the seat back frame. Installation Procedure 1. Install the rear seat back pad on the seat back frame. 2. Install the rear seat back cover to the rear seat back pad. Refer to Rear Seat Back Cushion Cover Replacement (Non Folding) (See: Seat Cover/Service and Repair/Rear Seat Back Cushion Cover Replacement (Non Folding))Rear Seat Back Cushion Cover Replacement (Folding) ( See: Seat Cover/Service and Repair/Rear Seat Back Cushion Cover Replacement (Folding)). 3. Install the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Rear Seat Back Cushion Replacement (Folding)). Seat Cushion Outer Trim Panel Replacement Seat Cushion Outer Trim Panel Replacement Removal Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12360 1. Remove the front seat back recliner handle, using a small, flat-bladed tool. 2. Remove the front seat lumbar knob by pulling it off. 3. Remove the screw from the rear of the front seat cushion trim panel. 4. Use a small, flat-bladed tool to remove the push-in retainer from the front of the front seat cushion trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12361 5. Pull off the front seat cushion trim panel to release the two retaining clips located on each side the recliner handle hole. 6. Remove the power seat switch from the front seat cushion trim panel, if equipped. Refer to Power Seat Switch Replacement (See: Power Seat Switch/Service and Repair). 7. Remove the heated seat switch from the front seat cushion trim panel, if equipped. 8. Remove the lumbar control switch from the front seat cushion trim panel, if equipped. Refer to Lumbar Switch Replacement (See: Service and Repair/Lumbar Switch Replacement). 9. Remove the front seat cushion trim panel from the vehicle. Installation Procedure 1. Install the power seat switch to the front seat cushion trim panel, if equipped. Refer to Power Seat Switch Replacement (See: Power Seat Switch/Service and Repair). 2. Install the lumbar control switch to the front seat cushion trim panel, if equipped. 3. Install the heated seat switch to the front seat cushion trim panel, if equipped. 4. Install the seat cushion trim panel, pressing in until the two retaining clips are fully seated. Notice: Refer to Fastener Notice in Cautions and Notices. 5. Install the front cushion trim panel rear screws. Tighten the front seat cushion trim panel screws to 3 Nm (27 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12362 6. Install the push-in retainer to the front of the front seat cushion trim panel, pressing into place until fully seated. 7. Install the front seat lumbar knob, pressing into place until fully seated. 8. Install the front seat back recliner handle, pressing into place until fully seated. Front Seat Cushion Replacement Front Seat Cushion Replacement Removal Procedure 1. Remove the front seat from the vehicle. Refer to the following procedures: * Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket) * Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement) 2. Remove the front seat cushion cover from the front seat cushion. Refer to Front Seat Cushion Cover Replacement (Bucket Seat) (See: Seat Cover/Service and Repair/Front Seat Cushion Cover Replacement (Bucket Seat))Front Seat Cushion Cover Replacement (Split Bench) (See: Seat Cover/Service and Repair/Front Seat Cushion Cover Replacement (Split Bench)). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12363 3. Remove the hog rings from the front seat cushion cover. 4. Remove the front seat cushion from the front seat frame. Installation Procedure 1. Position the front seat cushion to the front seat frame. 2. Install the hog rings to the front seat cushion cover. 3. Install the front seat cushion cover to the front seat cushion. Refer to Front Seat Cushion Cover Replacement (Bucket Seat) (See: Seat Cover/Service and Repair/Front Seat Cushion Cover Replacement (Bucket Seat))Front Seat Cushion Cover Replacement (Split Bench) (See: Seat Cover/Service and Repair/Front Seat Cushion Cover Replacement (Split Bench)). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12364 4. Install the front seat to the vehicle. Refer to the following procedures: * Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket) * Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement) Rear Seat Back Cushion Pad Replacement (Folding) Rear Seat Back Cushion Pad Replacement (Folding) Removal Procedure 1. Remove the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Rear Seat Back Cushion Replacement (Folding)). 2. Remove the right and/or left rear seat back cover. Refer to Rear Seat Back Cushion Cover Replacement (Non Folding) (See: Seat Cover/Service and Repair/Rear Seat Back Cushion Cover Replacement (Non Folding))Rear Seat Back Cushion Cover Replacement (Folding) (See: Seat Cover/Service and Repair/Rear Seat Back Cushion Cover Replacement (Folding)). 3. Remove the right and/or left rear seat back frame from the rear seat back pad. Installation Procedure 1. Install the rear seat back frame to the rear seat back pad. 2. Reposition the rear seat back release cable pull strap to the right rear seat back pad. 3. Install the right and/or left rear seat back cover. Refer to Rear Seat Back Cushion Cover Replacement (Non Folding) (See: Seat Cover/Service and Repair/Rear Seat Back Cushion Cover Replacement (Non Folding))Rear Seat Back Cushion Cover Replacement (Folding) (See: Seat Cover/Service and Repair/Rear Seat Back Cushion Cover Replacement (Folding)). 4. Install the rear seat back. Refer to Rear Seat Back Cushion Replacement (Non Folding) (See: Rear Seat Back Cushion Replacement (Non Folding))Rear Seat Back Cushion Replacement (Folding) (See: Rear Seat Back Cushion Replacement (Folding)). Rear Seat Back Cushion Replacement (Folding) Rear Seat Back Cushion Replacement (Folding) Removal Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12365 1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Rear Seat Cushion Replacement). 2. Remove the nuts from the rear seat retainer at the bottom of the rear seat back. 3. Fold the rear seat back cushions down. 4. Remove the bolts from the rear seat latches. 5. Remove the rear seat latches from the rear seat back. 6. Fold the rear seat back cushions up. 7. Reposition the seat belts from the rear seat back. 8. Remove the rear seat back from the vehicle. Installation Procedure 1. Position the rear seat back to the vehicle. 2. Reposition the seat belts to the rear seat back. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the nuts to the rear seat retainer at the bottom of the rear seat back. Tighten the nuts to the rear seat retainer to 10 Nm (89 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12366 4. Fold the rear seat back cushions down. 5. Install the rear seat latches to the rear seat back. 6. Install the rear seat back latch bolts to the rear seat latches. Tighten the rear seat back latch bolts to 6 Nm (53 lb in). 7. Fold the rear seat back cushions up. 8. Inspect the rear seat for proper operation. 9. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Rear Seat Cushion Replacement). Rear Seat Back Cushion Replacement (Non Folding) Rear Seat Back Cushion Replacement (Non Folding) Removal Procedure 1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Rear Seat Cushion Replacement). 2. Remove the nuts from the rear seat retainer at the bottom of the rear seat back. 3. Grasp the bottom of the rear seat back and lift upward to disengage offsets on the upper frame bar from the hangers. Lift the rear seat back upwards to remove from the rear shelf. 4. Remove the rear seat back from the vehicle. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12367 1. Position the rear seat back to the vehicle. 2. Hook the seat back upper frame to the hangers on the rear shelf. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the rear seat back nuts. Tighten the rear seat back nuts to 10 Nm (89 lb in). 4. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Rear Seat Cushion Replacement). Rear Seat Cushion Replacement Rear Seat Cushion Replacement Removal Procedure 1. Pull the tabs on the rear seat cushion retainers in order to release the rear seat cushion. 2. Remove the rear seat cushion by lifting up and pulling out of the retainer. 3. Remove the rear seat cushion from the vehicle. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12368 1. Align the seat belts to the notches in the rear seat cushion. 2. Position the rear seat cushion to the retainers. 3. Install the rear seat cushion to the retainers, engaging the right side first then the left side. 4. Inspect the rear seat cushion for proper installation. Rear Seat Cushion Cover Replacement Rear Seat Cushion Cover Replacement Removal Procedure 1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Rear Seat Cushion Replacement). 2. Remove the hog rings from the rear seat cushion cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12369 3. Reach inside of the rear seat cushion cover in order to unfasten the hook and the loop retainers securing the rear seat cushion cover to the pad. 4. Remove the rear seat cushion cover from the pad. Installation Procedure 1. Position the rear seat cushion cover to the pad. 2. Align the alignment marks on the rear seat cushion cover to the alignment marks on the pad. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12370 3. Pull the rear seat cushion cover over the pad and aline the hook and the loop retainers. 4. Pull the rear seat cushion cover over the pad and pull over and under the edge. 5. Use firm hand pressure in order to fasten the hook and the loop retainers, securing the rear seat cushion cover to the pad. 6. Align the alignment marks on the rear seat cushion cover to the alignment marks on the pad, on the back side. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Back Cushion Pad Replacement > Page 12371 7. Install the hog rings to the rear seat cushion cover. 8. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Rear Seat Cushion Replacement). Rear Seat Cushion Retainer Replacement Rear Seat Cushion Retainer Replacement Removal Procedure 1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Rear Seat Cushion Replacement). 2. Push down and back on the front of the seat cushion retainer to release the retainer from the floor. 3. Remove the seat cushion retainer from the floor. Installation Procedure 1. Install the rear seat cushion retainers into the floor, pressing in until fully seated. 2. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Rear Seat Cushion Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Component Locations Seat Heater: Component Locations Heated Seat Heater Element Located in back of seat & Seat Bottom. Heater Seat Thermistor Located in back of seat & Seat Bottom. Heated Seat Relay Module Locations View RPO KA1/AR9: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Component Locations > Page 12376 Seat Heater: Connector Locations Heated Seat Cushion Back Element Connector (RPO KA1) Locations View RPO KA1: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Heated Seat Cushion Element Connector (RPO KA1) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Component Locations > Page 12377 Locations View RPO KA1: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Page 12378 Seat Heater: Service and Repair Front Seat Heater Element Replacement 1. The seat heating element is sewn into the front seat back cover and the front seat cushion cover. 2. The seat heating element must be serviced as a unit. Refer to the following procedures for replacement: * For the front seat back cover, refer to Driver or Passenger Seat Back Cushion Cover Replacement (See: Seat Cover/Service and Repair/Driver or Passenger Seat Back Cushion Cover Replacement). * For the front seat cushion cover, refer to Front Seat Cushion Cover Replacement (Bucket Seat) (See: Seat Cover/Service and Repair/Front Seat Cushion Cover Replacement (Bucket Seat))Front Seat Cushion Cover Replacement (Split Bench) (See: Seat Cover/Service and Repair/Front Seat Cushion Cover Replacement (Split Bench)). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Replacement Removal Procedure 1. Remove the front seat adjuster to floor pan bolts. 2. Tilt the seat forward. 3. Disconnect the electric connectors from the heated seat module. 4. Cut the tie straps to the module. 5. Remove the heated seat module. Installation Procedure 1. Position the heated seat module under the seat. 2. Connect the electric connectors to the heated seat module. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Page 12382 3. Install new tie straps to the module. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the front bucket seat adjuster-to-floor pan bolts. Tighten the front bucket seat adjuster-to-floor pan bolts to 42 Nm (31 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Locations Seat Heater Relay: Locations Below the seat. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Heated Seat Switch Seat Heater Switch: Locations Heated Seat Switch On the LH side of the seat. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Heated Seat Switch > Page 12390 Seat Heater Switch: Locations Heated Seat Switch, Driver (2-Door) Mounted on the center console. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Heated Seat Switch > Page 12391 Seat Heater Switch: Locations Heated Seat Switch, Driver (4-Door) On the LH side of the seat. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Heated Seat Switch > Page 12392 Seat Heater Switch: Locations Driver Heated Seat Switch Locations View RPO KA1: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Heated Seat Switch On the LH side of the seat. Heated Seat Switch, Driver (2-Door) Mounted on the center console. Heated Seat Switch, Driver (4-Door) On the LH side of the seat. Heated Seat Switch, Passenger (2-Door) Mounted on the center console. Heated Seat Switch, Passenger (4-Door) On the RH side of the seat. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Heated Seat Switch, Driver Connector Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Heated Seat Switch, Driver Connector > Page 12395 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Component Locations Power Door Lock Switch: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Component Locations > Page 12401 Locations View Center of the front door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Component Locations > Page 12402 Power Door Lock Switch: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Component Locations > Page 12403 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > LF Door Lock Switch LF Door Lock Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > LF Door Lock Switch > Page 12406 RF Door Lock Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures Power Door Lock Switch: Procedures REMOVAL PROCEDURE 1. Remove the inside door handle bezel. 2. Remove the power door lock switch from the inside door handle bezel using a small, flat-bladed tool in order to release the retainers. 3. Disconnect the electrical connector from the power door lock switch. INSTALLATION PROCEDURE 1. Install the power door lock switch to the inside door handle bezel pressing into place until fully seated. 2. Connect the electrical connector to the power door lock switch. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 12409 3. Install the inside door handle bezel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 12410 Power Door Lock Switch: Removal and Replacement Door Lock Switch Replacement (Impala) Removal Procedure 1. Remove the inside door handle bezel. Refer to Door Inside Handle Bezel Replacement (Impala) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Door Inside Handle Bezel Replacement). 2. Remove the power door lock switch from the inside door handle bezel using a small, flat-bladed tool in order to release the retainers. 3. Disconnect the electrical connector from the power door lock switch. Installation Procedure 1. Install the power door lock switch to the inside door handle bezel pressing into place until fully seated. 2. Connect the electrical connector to the power door lock switch. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 12411 3. Install the inside door handle bezel. Refer to Door Inside Handle Bezel Replacement (Impala) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Door Inside Handle Bezel Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Outside Rearview Mirror Remote Control Switch Power Mirror Switch: Locations Outside Rearview Mirror Remote Control Switch Front top of the driver's door panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Outside Rearview Mirror Remote Control Switch > Page 12416 Power Mirror Switch: Locations Outside Remote Control Rearview Mirror Switch Locations View Front top of the left front door panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 12417 Power Mirror Switch: Service and Repair REMOVAL PROCEDURE 1. Remove the front door pull cup from the front door inner trim panel. 2. Disconnect the electrical connectors from the power mirror switch. 3. Remove the power mirror switch from the front door pull cup, using a small flat-bladed tool at the side of the mirror switch in order to release the mirror control switch retainer. 4. Remove the power mirror switch from the front door pull cup. INSTALLATION PROCEDURE 1. Install the power mirror switch to the front door pull cup pressing into place until fully seated. 2. Connect the electrical connectors to the power mirror switch. 3. Install the front door pull cup to the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver Seat Adjuster Switch Driver Seat Adjuster Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver Seat Adjuster Switch > Page 12422 Passenger Seat Adjuster Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 12423 Power Seat Switch: Service and Repair Power Seat Switch Replacement Removal Procedure 1. Remove the front seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seats/Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). 2. Remove the power front seat switch from the front seat outer trim panel, using a small flat bladed tool. 3. Disconnect the electrical connector from the power front seat switch. 4. Remove the power front seat switch from the vehicle. Installation Procedure 1. Connect the electrical connector to the power front seat switch. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 12424 2. Install the power front seat switch to the front seat outer trim panel, pressing into place until fully seated. 3. Install the front seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seats/Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Heated Seat Switch Seat Heater Switch: Locations Heated Seat Switch On the LH side of the seat. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Heated Seat Switch > Page 12429 Seat Heater Switch: Locations Heated Seat Switch, Driver (2-Door) Mounted on the center console. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Heated Seat Switch > Page 12430 Seat Heater Switch: Locations Heated Seat Switch, Driver (4-Door) On the LH side of the seat. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Heated Seat Switch > Page 12431 Seat Heater Switch: Locations Driver Heated Seat Switch Locations View RPO KA1: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Heated Seat Switch On the LH side of the seat. Heated Seat Switch, Driver (2-Door) Mounted on the center console. Heated Seat Switch, Driver (4-Door) On the LH side of the seat. Heated Seat Switch, Passenger (2-Door) Mounted on the center console. Heated Seat Switch, Passenger (4-Door) On the RH side of the seat. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Heated Seat Switch, Driver Connector Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Heated Seat Switch, Driver Connector > Page 12434 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Diagrams > Sunroof Limit Switch, C5 Sunroof Limit Switch, C5 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Diagrams > Sunroof Limit Switch, C5 > Page 12440 Sunroof Limit Switch, C4 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Sunroof / Moonroof Switch: Locations Center of the windshield header. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions Sunroof / Moonroof Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12446 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12447 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12448 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12449 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12450 Sunroof / Moonroof Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12451 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12452 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12453 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12454 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12455 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12456 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12457 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12458 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12459 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12460 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12461 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12462 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12463 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12464 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12465 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12466 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12467 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12468 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12469 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12470 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12471 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12472 Sunroof / Moonroof Switch: Electrical Diagrams Power Sunroof Schematics: Without Driver Information Center (DIC) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12473 Power Sunroof Schematics: With Driver Information Center (DIC) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Switch Replacement - Sunroof Position Encoding System Sunroof / Moonroof Switch: Service and Repair Switch Replacement - Sunroof Position Encoding System TOOLS REQUIRED J 41718 Sunroof Timing Pins REMOVAL PROCEDURE IMPORTANT: ^ The sunroof Positioning Encoding Switch (PES) (3) is aligned to the drive cables. The YES switch comes from the factory set to the glass panel CLOSED position. A position lock pin (1) has been installed on the top of the YES switch. The pin (1) must remain until after the installation of the actuator and of the YES switch. The pin locks the drive gears in place and must be removed before operation of the sunroof module. ^ If you reuse a YES switch, place the sunroof glass panel in the CLOSED position. Install the sunroof timing pins J41718. Install a position lock pin, or install 2 wires, such as the ends of a paper clip, then remove the YES switch from the sunroof module. The YES switch timing will be lost if you do not follow this procedure. 1. Position the sunroof glass panel to the closed position. 2. Remove the sunroof module from the vehicle. IMPORTANT: Before removing the YES switch from the sunroof module, the J 41718 sunroof timing pins must be installed to lock the cable/cam mechanism into position. 3. The cable/cam mechanisms on both sides of the glass contain a set of timing holes. These holes are aligned to the sunroof glass panel in the CLOSED position. Remove the left and right side front sunroof glass panel screws. Use a flat-bladed tool to push the cable/cam mechanisms forward or rearward to align with the holes. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Switch Replacement - Sunroof Position Encoding System > Page 12476 Install the J41718 sunroof timing pins into the left and right sunroof glass panel screw holes. Install the position lock pin or install 2 wires, such as the ends of a paper clip, to the YES switch before removal of the switch. 4. Remove the sunroof actuator. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Switch Replacement - Sunroof Position Encoding System > Page 12477 Sunroof / Moonroof Switch: Service and Repair Power Sunroof Switch Replacement (W/O Overhead Console) REMOVAL PROCEDURE 1. Grasp the power sunroof switch on the left and right sides. IMPORTANT: The switch must be rotated, pulled down on the left side, to be removed. 2. Use 2, small, flat-bladed tools in order to disengage the clips which are located at the front and rear of the power sunroof switch. Hold the flat-bladed tools parallel to the roof and push straight in. 3. Rotate the power sunroof switch toward the left side to disengage it from the mounting bracket and pull down. 4. Disconnect the electrical connector from the power sunroof switch. 5. Remove the power sunroof switch from the vehicle. INSTALLATION PROCEDURE 1. Connect the electrical connector to the power sunroof switch. 2. Rotate the power sunroof switch back into the vehicle. 3. Firmly push the power sunroof switch into the headliner until fully seated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Switch Replacement - Sunroof Position Encoding System > Page 12478 Sunroof / Moonroof Switch: Service and Repair Power Sunroof Switch Replacement (With Overhead Console) REMOVAL PROCEDURE IMPORTANT: The driver information center control module, and the power sunroof switch is serviced as a complete part. 1. Remove the overhead console. 2. Remove the driver information center control module, containing the power sunroof switch from the overhead console. INSTALLATION PROCEDURE 1. Install the driver information center control module, containing the power sunroof switch to the overhead console. 2. Install the overhead console. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Component Locations Trunk / Liftgate Switch: Component Locations Rear Compartment Lid Ajar Indicator Switch Center of the rear compartment lid. Rear Compartment Lid Release Switch Locations View Left side of the instrument panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Component Locations > Page 12483 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 12484 Rear Compartment Lid Ajar Indicator Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Rear Compartment Lid Ajar Switch Replacement Trunk / Liftgate Switch: Service and Repair Rear Compartment Lid Ajar Switch Replacement Rear Compartment Lid Ajar Switch Replacement REMOVAL PROCEDURE 1. Open the rear compartment lid. 2. Remove the rear compartment lid latch. Refer to Latch Replacement - Rear Compartment Lid. 3. Remove the rear compartment lid ajar lamp/switch to rear compartment lid latch screw (5). 4. Remove the compartment lid ajar lamp/switch (6) from the rear compartment lid latch (8). INSTALLATION PROCEDURE 1. Position the rear compartment lid ajar lamp/switch (6) to the rear compartment lid latch (8). 2. Install the rear compartment lid ajar lamp/switch to rear compartment lid latch screw (5). Tighten Tighten the rear compartment lid ajar lamp/switch to rear compartment lid latch screw to 5 N.m (44 lb in). 3. Install the rear compartment lid latch. 4. Close the rear compartment lid. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Rear Compartment Lid Ajar Switch Replacement > Page 12487 Trunk / Liftgate Switch: Service and Repair Rear Compartment Lid Switch Replacement Rear Compartment Lid Switch Replacement REMOVAL PROCEDURE 1. Release the LH instrument panel (IP) insulator tabs from the lower IP trim pad retainers for access. 2. Remove the LH fuse block access cover. 3. Remove the steering column opening filler panel screws. 4. Release the steering column opening filler panel retainers from the IP lower trim panel. Carefully lower the steering column opening filler panel away from the IP lower trim panel. 5. Disconnect the electrical connector from the rear compartment release switch. 6. Remove the rear compartment release switch. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Rear Compartment Lid Ajar Switch Replacement > Page 12488 1. Install the rear compartment release switch. 2. Connect the electrical connector to the rear compartment release switch. 3. Align the steering column opening filler panel to the instrument panel (IP) lower trim panel. Install the steering column opening filler panel retainers to the IP lower trim panel. 4. Install the steering column opening filler panel screws. Tighten Tighten the steering column opening filler panel screws to 2 N.m (18 lb in). 5. Install the LH IP insulator tabs to the lower IP trim pad retainers. 6. Install the LH fuse block access cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Splash Guard > Component Information > Service and Repair > Engine Splash Shield Replacement (Right) Splash Guard: Service and Repair Engine Splash Shield Replacement (Right) Engine Splash Shield Replacement (Right) Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Use J 38778 to remove the push-in retainers holding the engine splash shield to the lower flange of the engine compartment side rail. 3. For the Impala, remove the front fender liner. Refer to Front Fender Liner Replacement (See: Fender/Front Fender/Front Fender Liner/Service and Repair). 4. Remove the engine splash shield from the lower flange of the engine compartment side rail. Installation Procedure 1. Install the engine splash shield to the lower flange of the engine compartment side rail. 2. Align the holes in the engine splash shield to the holes in the outboard side engine compartment side rail. 3. Insert the push-in retainers to the engine splash shield. 4. For the Impala, install the front fender liner. Refer to Front Fender Liner Replacement (See: Fender/Front Fender/Front Fender Liner/Service and Repair). 5. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Splash Guard > Component Information > Service and Repair > Engine Splash Shield Replacement (Right) > Page 12493 Splash Guard: Service and Repair Engine Splash Shield Replacement (Left) Engine Splash Shield Replacement (Left) Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Use J 38778 to remove the push-in retainers holding the engine splash shield to the lower flange of the engine compartment side rail. 3. Remove the engine splash shield from the lower flange of the engine compartment side rail. Installation Procedure 1. Install the engine splash shield to the lower flange of the engine compartment side rail. 2. Align the holes in the engine splash shield to the holes in the outboard side engine compartment side rail. 3. Install the push-in retainers to the engine splash shield. 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair Spoiler: Service and Repair Rear Spoiler Replacement (Impala) Tools Required J 25070 Heat Gun Removal Procedure Notice: Use of harsh chemicals when cleaning can damage exterior lamps. Suggested cleaners are a mild soap and water, or Varnish Makers and Painters (VM&P;) Naptha. VM&P; Naptha is a specific type of naptha and should not be substituted by any other naptha. 1. Open the rear compartment. 2. Remove the nuts from the rear end spoiler studs. 3. Heat the rear end spoiler mounting points from the inside, using J 25070 152 mm (6 in) from surface. Apply heat using a circular motion for about 30 seconds. 4. Remove the rear end spoiler from the rear compartment lid surface using a small wood or plastic flat-bladed tool. Do NOT damage the paint. 5. Remove the rear end spoiler from the rear compartment lid. 6. Clean the rear end spoiler adhesive from the rear compartment lid and/or the rear end spoiler using 3M(TM) Scotch Brite molding adhesive remover disk, 3M(TM) P/N 07501, or equivalent. 7. Clean the body panel using VM&P; Naphtha in order to remove any adhesive. Wipe the surface dry with a clean, lint-free cloth. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Page 12498 1. Warm the rear compartment lid with J 25070 from the outside, to a minimum of 21°C (70°F). Important: Do not touch the adhesive backing. 2. Peel the backing from the mounting surfaces of the rear end spoiler. 3. Align the rear end spoiler studs to the holes in the rear compartment lid. 4. Install the rear end spoiler to the rear compartment lid, pressing into place until the adhesive is fully seated. 5. Open the rear compartment. Notice: Refer to Fastener Notice in Cautions and Notices. Important: Use new nuts/mastic washers in order to avoid a possible water leak. 6. Install the nuts to the rear end spoiler. Tighten the rear end spoiler nuts to 6 Nm (53 lb in). 7. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Strut Tower Brace > Component Information > Service and Repair Strut Tower Brace: Service and Repair Cross Vehicle Brace Replacement Removal Procedure 1. Open the hood. 2. Remove the nuts from the cross vehicle brace. 3. Remove the cross vehicle brace from the vehicle. Important: Be careful, the stud plates may fall out and possibly get caught under the vehicle during the removal. 4. Remove the stud plates push on nuts from the studs. 5. Remove the stud plates from the vehicle. Installation Procedure Important: The stud plates will require an assistant to hold the stud plates during the installation of the push on nuts. 1. Install the stud plates to the vehicle. 2. Install the stud plates push on nuts to the studs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Strut Tower Brace > Component Information > Service and Repair > Page 12503 3. Install the cross vehicle brace to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the nuts to the cross vehicle brace. Tighten the cross vehicle brace nuts to 18 Nm (13 lb ft). 5. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Plenum Water Deflector Replacement Cowl Moulding / Trim: Service and Repair Plenum Water Deflector Replacement Plenum Water Deflector Replacement Removal Procedure 1. Open the hood. 2. Remove the right side of the air inlet grille. Refer to Air Inlet Grille Panel Replacement (See: Air Inlet Grille Panel Replacement). 3. Remove the plenum chamber deflector from the pinch-weld flange, by lifting up and out. Installation Procedure 1. Install the plenum chamber deflector to the pinch-weld flange. 2. Install the right side of the air inlet grille. Refer to Air Inlet Grille Panel Replacement (See: Air Inlet Grille Panel Replacement). 3. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Plenum Water Deflector Replacement > Page 12510 Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Air Inlet Grille Panel Replacement Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the hood. 2. Remove the wiper arms. Refer to Windshield Wiper Arm Replacement in Wipers/Washer Systems. 3. Disconnect the windshield wiper washer hose from the air inlet grille. 4. Use the J 38778 to remove the push-in retainers from the air inlet grille. 5. Remove the air inlet grille from the vehicle. Installation Procedure 1. Install the air inlet grille to the vehicle. 2. Install the push-in retainers to the air inlet grille. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Plenum Water Deflector Replacement > Page 12511 3. Install the windshield wiper washer hose to the air inlet grille. 4. Install the wiper arms. Refer to Windshield Wiper Arm Replacement in Wipers/Washer Systems. 5. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Opening Weatherstrip Replacement Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement Front Door Opening Weatherstrip Replacement (Impala) Removal Procedure 1. Open the front door. 2. Remove the carpet retainers. Refer to Front Side Door Opening Floor Carpet Retainer Replacement (See: Interior Moulding / Trim/Carpet/Service and Repair/Front Side Door Opening Floor Carpet Retainer Replacement) in Interior Trim. 3. Remove the windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement) in Interior Trim. 4. Remove the upper center pillar trim panel. Refer to Center Pillar Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Trim Panel Replacement) in Interior Trim. 5. Remove the center lower trim panel. Refer to Center Pillar Lower Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Lower Trim Panel Replacement) in Interior Trim. 6. Remove the front door opening weatherstrip by pulling it off the pinch-weld flange. Installation Procedure 1. Position the front door opening weatherstrip to the pinch-weld flange. Starting at the center of the rocker panel area and moving in a clockwise direction press the front door opening weatherstrip to the pinch-weld flange until fully seated. Important: The joint butt ends must have no gap and be located in the center of the of the rocker panel area. 2. Install joint butt ends together. 3. Install the carpet retainers. Refer to Front Side Door Opening Floor Carpet Retainer Replacement (See: Interior Moulding / Trim/Carpet/Service and Repair/Front Side Door Opening Floor Carpet Retainer Replacement) in Interior Trim. 4. Install the windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement) in Interior Trim. 5. Install the upper center pillar trim panel. Refer to Center Pillar Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Trim Panel Replacement) in Interior Trim. 6. Install the center lower trim panel. Refer to Center Pillar Lower Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Lower Trim Panel Replacement) in Interior Trim. 7. Close the front door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Opening Weatherstrip Replacement > Page 12517 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Opening REMOVAL PROCEDURE 1. Open the front door. 2. Remove the carpet retainers. 3. Remove the windshield garnish molding. 4. Remove the upper center pillar trim panel. 5. Remove the center lower trim panel. 6. Remove the front door opening weatherstrip by pulling it off the pinch-weld flange. INSTALLATION PROCEDURE 1. Position the front door opening weatherstrip to the pinch-weld flange. Starting at the center of the rocker panel area and moving in a clockwise direction press the front door opening weatherstrip to the pinch-weld flange until fully seated. IMPORTANT: The joint butt ends must have no gap and be located in the center of the of the rocker panel area. 2. Install joint butt ends together. 3. Install the carpet retainers. 4. Install the windshield garnish molding. 5. Install the upper center pillar trim panel. 6. Install the center lower trim panel. 7. Close the front door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Opening Weatherstrip Replacement > Page 12518 Front Door Weatherstrip: Service and Repair Door Bottom Auxiliary Sealing Strip Replacement (Front) Door Bottom Auxiliary Sealing Strip Replacement (Impala and Monte Carlo Front) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the front door. 2. Remove the push-in retainers from the front door bottom auxiliary sealing strip using the J 38778 . 3. Remove the door bottom auxiliary sealing strip from the front door. Installation Procedure 1. Install the front door bottom auxiliary sealing strip to the front door. 2. Stretch the door bottom auxiliary sealing strip in order to align the push-in retainers to the holes in the front door. 3. Install the push-in retainers to the door bottom auxiliary sealingstrip. 4. Close the front door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Opening Weatherstrip Replacement > Page 12519 Front Door Weatherstrip: Service and Repair Sealing Strip Replacement - Front Door Window Belt Outer REMOVAL PROCEDURE 1. Remove the outside rearview mirror. 2. Remove the rear screw from the front door outer belt sealing strip. 3. Remove the front door outer belt sealing strip. INSTALLATION PROCEDURE 1. Position the front door outer belt sealing strip to the front door pinch-weld flange. 2. Install the front door outer belt sealing strip to the front door pinch-weld flange pressing into place until fully seated. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw to the rear of the front door outer belt sealing strip. Tighten Tighten the outer belt sealing strip screw to 2 N.m (18 lb in). 4. Install the outside rearview mirror. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window Front Door Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Window REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Remove the front door water deflector. 3. Remove the front door outer belt sealing strip. 4. Remove the front door window. 5. Remove the screws from the front door window channel. 6. Remove the front door window channel from the front door frame. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 12524 7. Remove the front door channel from the front door. 8. Remove the screw from the front door rear window channel. 9. Remove the front door rear window channel from the front door slot by pulling down to disengage the retainer clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 12525 10. Remove the front door rear window channel from the front door through the access hole in the inner front door panel. INSTALLATION PROCEDURE 1. Position the front door window channel front channel into the front door. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 12526 2. Install the front door window channel screws. Tighten Tighten the front door window channel screws to 10 N.m (89 lb in). 3. Install the front door window channel to the front door starting in the top corner working out in both directions. Firmly seat the front door window channel to the front door. 4. Install the front door rear window channel to the front door through the access hole in the inner front door panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 12527 5. Install the front door rear window channel to the front door slot by pushing up to engage the retainer clip. 6. Install the screw to the front door rear window channel. Tighten Tighten the front door weatherstrip channel screws to 10 N.m (89 lb in). 7. Install the front door window. 8. Inspect the front door window for proper operation. 9. Install the front door outer belt sealing strip. 10. Install the front door water deflector. 11. Install the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 12528 Front Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Front Side Door Window Weatherstrip Replacement (Impala) Removal Procedure 1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (Impala) See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 2. Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement (Impala) See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 3. Remove the front door outer belt sealing strip. Refer to Front Side Door Window Belt Outer Sealing Strip Replacement (Impala) (See: Door Window Sealing Strip). 4. Remove the front door window. Refer to Front Side Door Window Replacement (Impala) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Window Glass/Service and Repair/Front Side Door Window Replacement). 5. Remove the screws from the front door window channel. 6. Remove the front door window channel from the front door frame. 7. Remove the front door window channel from the front door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 12529 8. Remove the screw from the front door rear window channel. 9. Remove the front door rear window channel from the front door slot by pulling down to disengage the retainer clip. 10. Remove the front door rear window channel from the front door through the access hole in the inner front door panel. Installation Procedure 1. Position the front door window channel front channel into the front door. Notice: Refer to Fastener Notice in Cautions and Notices. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 12530 2. Install the front door window channel screws. Tighten the front door window channel screws to 10 Nm (89 lb in). 3. Install the front door window channel to the front door starting in the top corner working out in both directions. Firmly seat the front door window channel to the front door. 4. Install the front door rear window channel to the front door through the access hole in the inner front door panel. 5. Install the front door rear window channel to the front door slot by pushing up to engage the retainer clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 12531 6. Install the screw to the front door rear window channel. Tighten the front door weatherstrip channel screws to 10 Nm (89 lb in). 7. Install the front door window. Refer to Front Side Door Window Replacement (Impala) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Window Glass/Service and Repair/Front Side Door Window Replacement). 8. Inspect the front door window for proper operation. 9. Install the front door outer belt sealing strip. Refer to Front Side Door Window Belt Outer Sealing Strip Replacement (Impala) (See: Door Window Sealing Strip). 10. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement (Impala) See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 11. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (Impala) See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 12532 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Front Side Door Window Belt Outer Sealing Strip Replacement (Impala) Removal Procedure 1. Remove the outside rearview mirror. Refer to Power Mirror Replacement (Impala) (See: Mirrors/Service and Repair/Power Mirror Replacement ). 2. Remove the rear screw from the front door outer belt sealing strip. 3. Remove the front door outer belt sealing strip. Installation Procedure 1. Position the front door outer belt sealing strip to the front door pinch-weld flange. 2. Install the front door outer belt sealing strip to the front door pinch-weld flange pressing into place until fully seated. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screw to the rear of the front door outer belt sealing strip. Tighten the outer belt sealing strip screw to 2 Nm (18 lb in). 4. Install the outside rearview mirror. Refer to Power Mirror Replacement (Impala) (See: Mirrors/Service and Repair/Power Mirror Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement Hood Weatherstrip: Service and Repair Hood Front Seal Replacement Hood Front Seal Replacement Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the hood. 2. Use J 38778 to remove the push-in retainers from the front air seal. 3. Remove the front air seal from the hood. Installation Procedure 1. Install the front air seal to the hood. 2. Install the push-in retainers to the front air seal into the hood. 3. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement > Page 12537 Hood Weatherstrip: Service and Repair Hood Rear Seal Replacement Hood Rear Seal Replacement Removal Procedure 1. Open the hood. 2. Pull the hood rear weatherstrip from the pinch-weld flange. 3. Remove the hood rear weatherstrip from the vehicle. Installation Procedure 1. Install the hood rear weatherstrip to the pinch-weld flange. 2. Press the hood rear weatherstrip onto the pinch-weld flange. 3. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement > Page 12538 Hood Weatherstrip: Service and Repair Seal Replacement - Plenum to Hood Seal Replacement - Plenum to Hood Removal Procedure 1. Open the hood. 2. Remove the right side of the air inlet grille. Refer to Air Inlet Grille Panel Replacement (See: Cowl/Cowl Moulding / Trim/Service and Repair/Air Inlet Grille Panel Replacement). 3. To remove the seal from the pinch-weld flange, start at the passenger side corner of the seal and pull forward and off of the pinch-weld flange. Installation Procedure 1. Align the seal to the pinch-weld flange. 2. Press to install the seal to the pinch-weld flange, start at the passenger side corner and work toward the center of the car. 3. Install the right side of the air inlet grille. Refer to Air Inlet Grille Panel Replacement (See: Cowl/Cowl Moulding / Trim/Service and Repair/Air Inlet Grille Panel Replacement). 4. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement > Page 12539 Hood Weatherstrip: Service and Repair Hood Rear Outer Seal Replacement Hood Rear Outer Seal Replacement Removal Procedure 1. Open the hood. 2. Pull the rear side hood seal from the pinch-weld flange and motor compartment flange. 3. Remove the rear side hood seal from the vehicle. 4. Using 3M(TM) P/N 8984 Adhesive Remover or equivalent, clean any adhesive from the pinch-weld flange and motor compartment flange surface. Installation Procedure 1. Remove the protective backing paper from the adhesive on the rear side hood seal. 2. Install the rear side hood seal to the pinch-weld flange and motor compartment flange. 3. Press the side rear hood seal onto the pinch-weld flange and motor compartment flange until the adhesive is fully adhered. 4. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door REMOVAL PROCEDURE 1. Open the rear door. 2. Remove the trim panels. 3. Remove the weatherstrip from the rear door opening by pulling the weatherstrip off the pinchweld flange. INSTALLATION PROCEDURE 1. Position the rear door opening weatherstrip to the pinchweld flange. Starting at the center of the rocker panel area and moving in a clockwise direction, press the weatherstrip to the pinchweld flange until fully seated. IMPORTANT: The joint butt ends must have no gap and must be located in the center of the of the rocker panel area. 2. Install the joint butt ends together. 3. Install the trim panels. 4. Close the rear door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 12544 Rear Door Weatherstrip: Service and Repair Door Bottom Auxiliary Sealing Strip Replacement (Rear) Door Bottom Auxiliary Sealing Strip Replacement (Impala Rear) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the rear door. 2. Remove the push-in retainers from the rear door bottom auxiliary sealingstrip using the J 38778 . 3. Remove the door bottom auxiliary sealingstrip from the rear door. Installation Procedure 1. Position the door bottom auxiliary weatherstrip to the rear door. 2. Stretch the door bottom auxiliary weatherstrip in order to align the push-in retainers to the holes in the door. 3. Install the push-in retainers to the door bottom auxiliary weatherstrip. 4. Close the rear door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 12545 Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement Rear Door Opening Weatherstrip Replacement (Impala) Removal Procedure 1. Open the rear door. 2. Remove the carpet retainers. Refer to Rear Side Door Opening Floor Carpet Retainer Replacement (See: Interior Moulding / Trim/Carpet/Service and Repair/Rear Side Door Opening Floor Carpet Retainer Replacement) in Interior Trim. 3. Remove the rear quarter upper trim panel. Refer to Quarter Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Upper Trim Panel Replacement) in Interior Trim. 4. Remove the rear quarter lower trim panel. Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Lower Rear Trim Panel Replacement) in Interior Trim. 5. Remove the upper center pillar trim panel. Refer to Center Pillar Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Trim Panel Replacement) in Interior Trim. 6. Remove the center lower trim panel. Refer to Center Pillar Lower Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Lower Trim Panel Replacement) in Interior Trim. 7. Remove the rear door opening weatherstrip by pulling it off the pinchweld flange. Installation Procedure 1. Position the rear door opening weatherstrip to the pinchweld flange. Starting at the center of the rocker panel area and moving in a clockwise direction press the rear door opening weatherstrip to the pinchweld flange until fully seated. Important: The joint butt ends must have no gap and be located in the center of the of the rocker panel area. 2. Install joint butt ends together. 3. Install the rear quarter upper trim panel. Refer to Quarter Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Upper Trim Panel Replacement) in Interior Trim. 4. Install the rear quarter lower trim panel. Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Lower Rear Trim Panel Replacement) in Interior Trim. 5. Install the upper center pillar trim panel. Refer to Center Pillar Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Trim Panel Replacement) in Interior Trim. 6. Install the center lower trim panel. Refer to Center Pillar Lower Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Lower Trim Panel Replacement) in Interior Trim. 7. Install the carpet retainers. Refer to Rear Side Door Opening Floor Carpet Retainer Replacement (See: Interior Moulding / Trim/Carpet/Service Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 12546 and Repair/Rear Side Door Opening Floor Carpet Retainer Replacement) in Interior Trim. 8. Close the rear door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 12547 Rear Door Weatherstrip: Service and Repair Rear Side Door Window Outer Sealing Strip Replacement Rear Side Door Window Outer Sealing Strip Replacement (Impala) Removal Procedure 1. Position the rear window all the way down. 2. Remove the rear door trim panel to have access to these screws. Refer to Rear Side Door Trim Panel Replacement See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair 3. Remove the rear door outer belt sealing strip screws. 4. Remove the rear window outer belt sealing strip by pulling the sealing strip from the rear door pinch-weld flange. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 12548 1. Position the rear door outer belt sealing strip to the rear door pinch-weld flange. 2. Install the rear door outer belt sealing strip to the pinch-weld flange, pressing into place until full seated. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the rear door outer belt sealing strip screws. Tighten the rear door outer belt sealing strip screws to 2 Nm (18 lb in). 4. Install Rear door trim panel. Refer to Rear Side Door Trim Panel Replacement See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 12549 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door REMOVAL PROCEDURE 1. Open the rear door. 2. Remove the trim panels. 3. Remove the weatherstrip from the rear door opening by pulling the weatherstrip off the pinchweld flange. INSTALLATION PROCEDURE 1. Position the rear door opening weatherstrip to the pinchweld flange. Starting at the center of the rocker panel area and moving in a clockwise direction, press the weatherstrip to the pinchweld flange until fully seated. IMPORTANT: The joint butt ends must have no gap and must be located in the center of the of the rocker panel area. 2. Install the joint butt ends together. 3. Install the trim panels. 4. Close the rear door. Door Bottom Auxiliary Sealing Strip Replacement (Rear) Door Bottom Auxiliary Sealing Strip Replacement (Impala Rear) Tools Required Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 12550 J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the rear door. 2. Remove the push-in retainers from the rear door bottom auxiliary sealingstrip using the J 38778 . 3. Remove the door bottom auxiliary sealingstrip from the rear door. Installation Procedure 1. Position the door bottom auxiliary weatherstrip to the rear door. 2. Stretch the door bottom auxiliary weatherstrip in order to align the push-in retainers to the holes in the door. 3. Install the push-in retainers to the door bottom auxiliary weatherstrip. 4. Close the rear door. Rear Door Opening Weatherstrip Replacement Rear Door Opening Weatherstrip Replacement (Impala) Removal Procedure 1. Open the rear door. 2. Remove the carpet retainers. Refer to Rear Side Door Opening Floor Carpet Retainer Replacement (See: Interior Moulding / Trim/Carpet/Service and Repair/Rear Side Door Opening Floor Carpet Retainer Replacement) in Interior Trim. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 12551 3. Remove the rear quarter upper trim panel. Refer to Quarter Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Upper Trim Panel Replacement) in Interior Trim. 4. Remove the rear quarter lower trim panel. Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Lower Rear Trim Panel Replacement) in Interior Trim. 5. Remove the upper center pillar trim panel. Refer to Center Pillar Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Trim Panel Replacement) in Interior Trim. 6. Remove the center lower trim panel. Refer to Center Pillar Lower Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Lower Trim Panel Replacement) in Interior Trim. 7. Remove the rear door opening weatherstrip by pulling it off the pinchweld flange. Installation Procedure 1. Position the rear door opening weatherstrip to the pinchweld flange. Starting at the center of the rocker panel area and moving in a clockwise direction press the rear door opening weatherstrip to the pinchweld flange until fully seated. Important: The joint butt ends must have no gap and be located in the center of the of the rocker panel area. 2. Install joint butt ends together. 3. Install the rear quarter upper trim panel. Refer to Quarter Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Upper Trim Panel Replacement) in Interior Trim. 4. Install the rear quarter lower trim panel. Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Lower Rear Trim Panel Replacement) in Interior Trim. 5. Install the upper center pillar trim panel. Refer to Center Pillar Upper Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Trim Panel Replacement) in Interior Trim. 6. Install the center lower trim panel. Refer to Center Pillar Lower Trim Panel Replacement (Impala) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Lower Trim Panel Replacement) in Interior Trim. 7. Install the carpet retainers. Refer to Rear Side Door Opening Floor Carpet Retainer Replacement (See: Interior Moulding / Trim/Carpet/Service and Repair/Rear Side Door Opening Floor Carpet Retainer Replacement) in Interior Trim. 8. Close the rear door. Rear Side Door Window Outer Sealing Strip Replacement Rear Side Door Window Outer Sealing Strip Replacement (Impala) Removal Procedure 1. Position the rear window all the way down. 2. Remove the rear door trim panel to have access to these screws. Refer to Rear Side Door Trim Panel Replacement See: Doors, Hood and Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 12552 Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair 3. Remove the rear door outer belt sealing strip screws. 4. Remove the rear window outer belt sealing strip by pulling the sealing strip from the rear door pinch-weld flange. Installation Procedure 1. Position the rear door outer belt sealing strip to the rear door pinch-weld flange. 2. Install the rear door outer belt sealing strip to the pinch-weld flange, pressing into place until full seated. Notice: Refer to Fastener Notice in Cautions and Notices. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 12553 3. Install the rear door outer belt sealing strip screws. Tighten the rear door outer belt sealing strip screws to 2 Nm (18 lb in). 4. Install Rear door trim panel. Refer to Rear Side Door Trim Panel Replacement See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement TOOLS REQUIRED J 38778 Door Trim Pad Clip Remover REMOVAL PROCEDURE 1. Open the rear door. 2. Remove the push-in retainers from the rear door bottom auxiliary sealingstrip using the J 38778. 3. Remove the door bottom auxiliary sealingstrip from the rear door. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 12554 1. Position the door bottom auxiliary weatherstrip to the rear door. 2. Stretch the door bottom auxiliary weatherstrip in order to align the push-in retainers to the holes in the door. 3. Install the push-in retainers to the door bottom auxiliary weatherstrip. 4. Close the rear door. Sealing Strip Replacement - Door Bottom - Rear TOOLS REQUIRED J 38778 Door Trim Pad Clip Remover REMOVAL PROCEDURE 1. Open the rear door. 2. Remove the push-in retainers from the rear door bottom auxiliary sealingstrip using the J 38778. 3. Remove the door bottom auxiliary sealingstrip from the rear door. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door > Page 12555 1. Position the door bottom auxiliary weatherstrip to the rear door. 2. Stretch the door bottom auxiliary weatherstrip in order to align the push-in retainers to the holes in the door. 3. Install the push-in retainers to the door bottom auxiliary weatherstrip. 4. Close the rear door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window Rear Door Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door Window REMOVAL PROCEDURE 1. Place the rear window in the full down position. 2. Remove the rear door trim panel. 3. Remove the outer belt sealing strip. 4. Remove the rear window channel from the door. INSTALLATION PROCEDURE 1. Position the rear window channel to the rear door starting in the corner.Work outward in both directions. 2. Firmly seat the rear window channel to the rear door. 3. Inspect the rear door window for proper operation. 4. Install the outer belt sealing strip. 5. Install the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 12560 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Channel Rear Side Door Window Channel Retainer Replacement (Impala) Removal Procedure 1. Partially remove the upper portion of the rear door frame appliques. Refer to Rear Door Frame Applique Replacement (Impala Front) ()Rear Door Frame Applique Replacement (Impala Rear) (). 2. Pull downwards on the rear door window channel to gain access to the rivets. 3. Drill out the rivets. 4. Remove the forward screw to the rear window channel retainer. 5. Remove the rear window channel retainer from the rear door. Installation Procedure 1. Position the rear window weatherstrip retainer. 2. Push downwards on the rear door window channel to gain access to the rivets holes. 3. Install weather strip retainer rivets. 4. Install the rear door frame applique. Refer to Rear Door Frame Applique Replacement (Impala Front) ()Rear Door Frame Applique Replacement (Impala Rear) (). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 12561 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Rear Side Door Window Weatherstrip Replacement (Impala) Removal Procedure 1. Place the rear window in the full down position. 2. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair 3. Remove the outer belt sealing strip. Refer to Rear Side Door Window Outer Sealing Strip Replacement (Impala) (See: Rear Door Weatherstrip/Service and Repair/Rear Side Door Window Outer Sealing Strip Replacement). 4. Remove the rear window channel from the door. Installation Procedure 1. Position the rear window channel to the rear door starting in the corner. Work outward in both directions. 2. Firmly seat the rear window channel to the rear door. 3. Inspect the rear door window for proper operation. 4. Install the outer belt sealing strip. Refer to Rear Side Door Window Outer Sealing Strip Replacement (Impala) (See: Rear Door Weatherstrip/Service and Repair/Rear Side Door Window Outer Sealing Strip Replacement). 5. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 12562 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip REMOVAL PROCEDURE 1. Position the rear window all the way down. 2. Remove the rear door trim panel to have access to these screws. 3. Remove the rear door outer belt sealing strip screws. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 12563 4. Remove the rear window outer belt sealing strip by pulling the sealing strip from the rear door pinch-weld flange. INSTALLATION PROCEDURE 1. Position the rear door outer belt sealing strip to the rear door pinch-weld flange. 2. Install the rear door outer belt sealing strip to the pinch-weld flange, pressing into place until full seated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 12564 NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the rear door outer belt sealing strip screws. Tighten Tighten the rear door outer belt sealing strip screws to 1.5 N.m (13 lb in). 4. Install Rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Finishing Lace Replacement Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Finishing Lace Replacement REMOVAL PROCEDURE 1. Beginning at the joint, pull the sunroof opening trim lace from the headliner. 2. Remove the sunroof opening trim lace from the headliner. INSTALLATION PROCEDURE 1. Beginning at the joint, install the sunroof opening trim lace into place around the sunroof opening. 2. Ensure the sunroof trim lace is fully seated to the headliner. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Finishing Lace Replacement > Page 12569 Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Glass Panel Seal Replacement REMOVAL PROCEDURE 1. Remove the sunroof glass panel. 2. Remove the sunroof glass seal from the sunroof glass panel frame by pulling the sunroof glass seal away at one point and continuing around the perimeter of the sunroof glass panel frame. 3. Wipe the perimeter of the sunroof glass panel frame area with a clean, dampened cloth using window cleaner GM P/N 1050427, Canadian P/N 992727, or isopropyl alcohol in order to clean the surface of the perimeter of the sunroof glass panel frame. Allow to air dry. INSTALLATION PROCEDURE 1. Position the sunroof glass panel seal onto the sunroof glass panel frame. IMPORTANT: Ensure that the sunroof glass seal is properly seated around the entire perimeter of the sunroof glass panel frame. 2. Firmly press the sunroof glass seal into place. A small rubber hammer will help in the installation. 3. Install the sunroof glass panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Rear Compartment Lid Weatherstrip Replacement (Impala) Removal Procedure 1. Open the rear compartment. 2. Remove the rear compartment weatherstrip from the pinch-weld flange. Installation Procedure 1. Align the metal joint of the weatherstrip to the center of the rear compartment lid striker. Important: In order to minimize bulging conditions, avoid stretching the weatherstrip around the corners. 2. Install the rear compartment weatherstrip onto the pinch-weld flange, starting at the top center of the lid opening and working toward the bottom center. Use a rubber mallet in order to ensure that the weatherstrip is fully engaged to the pinch-weld flange. 3. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation Brake Switch (Cruise Control): Description and Operation The cruise control release switch and the stop lamp switch disengage the cruise control system. A cruise control release switch and a stop lamp switch are mounted on the brake pedal bracket. The switches disengage the system electrically when the brake pedal is pressed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Specifications Cruise Control Module: Specifications Cruise Control Module to Shock Tower Nuts 2 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Component Locations Cruise Control Module: Component Locations Locations View LH side of the engine compartment, near the strut tower. Left side of the engine compartment, on the strut tower. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Component Locations > Page 12582 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions Cruise Control Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12585 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12586 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12587 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12588 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12589 Cruise Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12590 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12591 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12592 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12593 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12594 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12595 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12596 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12597 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12598 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12599 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12600 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12601 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12602 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12603 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12604 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12605 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12606 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12607 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12608 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12609 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12610 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12611 Cruise Control Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12612 Cruise Control Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Description and Operation > General Information Cruise Control Module: Description and Operation General Information The cruise control system uses a cruise control module in order to obtain and hold any desired vehicle cruise speed above a minimum speed of 40 km/h (25 mph). The following 2 components within the module help achieve this function: ^ An electronic controller that performs the following functions: Monitors the vehicle speed. - Monitors the turn signal and the multifunction switch inputs. - Monitors the cruise control release and the brake switch inputs. - Operates the electric stepper motor. ^ A stepper motor which moves an internal band (linked to the throttle lever via the cruise control cable) in response to the controller in order to maintain the desired cruise speed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Description and Operation > General Information > Page 12615 Cruise Control Module: Description and Operation Vehicle Speed Sensor The Vehicle Speed Sensor (VSS) is mounted to the automatic transaxle. The VSS provides a low voltage Alternating Current (AC) signal to the Powertrain Control Module (PCM). The PCM converts the AC signal to a pulse width modulated Direct Current (DC) signal. The DC signal is sent to the cruise control module at a rate of 4,000 pulses per mile. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Description and Operation > Page 12616 Cruise Control Module: Service and Repair REMOVAL PROCEDURE The cruise control module is mounted to the left strut tower and must be serviced as a complete unit. 1. Remove the cruise control cable from the cruise control module. 2. Remove the electrical connector from the cruise control module. 3. Remove the cruise control module shock tower nuts. 4. Remove the cruise control module. INSTALLATION PROCEDURE 1. Install the cruise control module on the mounting studs located on the shock tower. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Description and Operation > Page 12617 2. Install the cruise control module mounting nuts. Tighten Tighten the cruise control module mounting nuts to 2 N.m (18 lb in). 3. Install the electrical connector to the cruise control module. 4. Install the cruise control cable to the cruise control module. 5. Adjust the cruise control cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation Cruise Control Servo Cable: Description and Operation The cruise control cable is adjustable and provides a physical connection between the following components: ^ The cruise control module ^ The engine throttle lever Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments > Cruise Control Cable Adjustment (3400) Cruise Control Servo Cable: Adjustments Cruise Control Cable Adjustment (3400) 1. Disengage the cruise control cable adjuster lock by spreading the adjuster lock tabs and pulling the adjuster lock out. 2. Slide the cruise control cable adjuster forward, away from the cruise control module. Remove as much cruise control cable slack as possible without moving the throttle lever. 3. Engage the cruise control cable adjuster lock by pushing the adjuster lock in. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments > Cruise Control Cable Adjustment (3400) > Page 12623 Cruise Control Servo Cable: Adjustments Cruise Control Cable Adjustment (3800) 1. Disengage the cruise control cable adjuster lock by clamping the side of the cruise control cable adjuster lock with a pair of pliers and pull the adjuster lock out. 2. Slide the adjuster forward to take slack out of the cable or slide adjuster backward to slacken the cable. Make adjustments without moving the throttle lever. 3. Engage the cruise control cable adjuster lock by pushing the adjuster lock in towards the throttle lever. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair > Cruise Control Cable Replacement (3400) Cruise Control Servo Cable: Service and Repair Cruise Control Cable Replacement (3400) REMOVAL PROCEDURE 1. Remove the cruise control from the throttle lever and the accelerator control cable bracket. 2. Remove the cruise control cable from the cruise control cable retainers. 3. Remove the cruise control cable from the module strap. 4. Remove the cruise control cable from the cruise control module by rotating the cruise control cable counterclockwise. 5. Remove the control cable from the engine. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair > Cruise Control Cable Replacement (3400) > Page 12626 1. Position the cruise control cable to the engine. 2. Install the cruise control cable to the cruise control module by rotating the cruise control cable clockwise. 3. Install the cruise control cable to the cruise control cable retainers. IMPORTANT: Ensure the module strap is not twisted during installation of the cable. 4. Install the cruise control cable to the cruise control module cable strap. 5. Install the cruise control cable to the throttle lever and the accelerator control cable bracket. 6. Adjust the cruise control cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair > Cruise Control Cable Replacement (3400) > Page 12627 Cruise Control Servo Cable: Service and Repair Cruise Control Cable Replacement (3800) REMOVAL PROCEDURE 1. Remove the cruise control from the throttle lever and the accelerator control cable bracket. 2. Remove the cruise control cable from the cruise control cable retainers. 3. Remove the cruise control cable from the cruise control module cable strap. 4. Remove the cruise control cable from the cruise control module by rotating the cruise control cable counterclockwise. 5. Remove the control cable from the engine. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair > Cruise Control Cable Replacement (3400) > Page 12628 1. Position the cruise control cable to the engine. 2. Install the cruise control cable to the module by rotating the cruise control cable clockwise. 3. Install the cruise control cable to the cruise control cable retainers. IMPORTANT: Ensure the module strap is not twisted during installation of the cable. 4. Install the cruise control cable to the cruise control module cable strap. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair > Cruise Control Cable Replacement (3400) > Page 12629 5. Install the cruise control cable to the throttle lever and the accelerator control cable bracket. 6. Adjust the cruise control cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations Cruise Control Switch: Component Locations Cruise Control ON/OFF Switch On the turn signal lever. On the steering wheel spoke. Cruise Control Release Switch Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations > Page 12634 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations > Page 12635 Locations View Behind the LH side of the instrument panel, on the brake pedal support. Cruise Control Resume/Accel Switch On the steering wheel spoke. Cruise Control Set/Cancel Switch On the steering wheel spoke. Cruise Control Steering Wheel Switch (LH) (SET/COAST) Lower Left side of steering wheel. Cruise Control Steering Wheel Switch (RH) (RESUME/ACCEL) Lower right side of steering wheel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations > Page 12636 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations > Page 12637 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations > Page 12638 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations > Page 12639 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions Cruise Control Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12642 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12643 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12644 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12645 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12646 Cruise Control Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12647 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12648 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12649 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12650 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12651 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12652 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12653 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12654 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12655 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12656 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12657 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12658 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12659 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12660 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12661 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12662 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12663 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12664 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12665 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12666 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12667 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12668 Cruise Control Release Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12669 Cruise Control Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Cruise Release Switch Replacement Cruise Control Switch: Service and Repair Cruise Release Switch Replacement REMOVAL PROCEDURE CAUTION: ^ Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components. ^ This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions: ^ Air bag deployment ^ Personal injury ^ Unnecessary SIR system repairs In order to avoid the above conditions, observe the following guidelines: ^ Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring. ^ If you are performing service on or near the SIR components or the SIR wiring, disable the SIR system. Refer to Disabling the SIR System in SIR. 1. Remove the driver side knee bolster panel. 2. Remove the electrical connector from the cruise control release switch. 3. Remove the cruise control release switch from the retainer in the brake pedal bracket. INSTALLATION PROCEDURE 1. Install the cruise control release switch to the retainer in the brake pedal bracket. 2. Install the electrical connector onto the cruise control release switch. 3. Adjust the cruise control release switch. 4. Install the driver side knee bolster panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Cruise Release Switch Replacement > Page 12672 Cruise Control Switch: Service and Repair Cruise Release Switch Adjustment IMPORTANT: The cruise control release switch and the stop lamp switch are adjusted together. Incorrect adjustment of either of these switches may cause premature brake lining wear or the cruise control system to not work properly. 1. Remove the left side insulator panel. 2. Press the brake pedal fully. 3. Push the switches into the retainers until the switches are fully seated. 4. Pull the brake pedal rearward against the pedal stop until the audible clicks can no longer be heard. 5. The following brake pedal travel distances can be used to validate the proper cruise control release switch and stop lamp switch adjustment. Cruise control release switch and the stop lamp switch contacts must actuate at 3.5 to 12.5 mm (1/8 to 1/2 in) of the brake pedal travel measured at the centerline of the brake pedal pad. Nominal actuation of the stop lamp switch contacts is about 4.5 mm (3/16 in) after the cruse control release switch actuation. 6. Install the left side insulator panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Specifications Cruise Control Module: Specifications Cruise Control Module to Shock Tower Nuts 2 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Component Locations Cruise Control Module: Component Locations Locations View LH side of the engine compartment, near the strut tower. Left side of the engine compartment, on the strut tower. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Component Locations > Page 12679 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions Cruise Control Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12682 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12683 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12684 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12685 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12686 Cruise Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12687 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12688 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12689 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12690 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12691 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12692 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12693 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12694 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12695 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12696 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12697 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12698 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12699 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12700 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12701 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12702 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12703 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12704 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12705 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12706 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12707 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12708 Cruise Control Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12709 Cruise Control Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Description and Operation > General Information Cruise Control Module: Description and Operation General Information The cruise control system uses a cruise control module in order to obtain and hold any desired vehicle cruise speed above a minimum speed of 40 km/h (25 mph). The following 2 components within the module help achieve this function: ^ An electronic controller that performs the following functions: Monitors the vehicle speed. - Monitors the turn signal and the multifunction switch inputs. - Monitors the cruise control release and the brake switch inputs. - Operates the electric stepper motor. ^ A stepper motor which moves an internal band (linked to the throttle lever via the cruise control cable) in response to the controller in order to maintain the desired cruise speed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Description and Operation > General Information > Page 12712 Cruise Control Module: Description and Operation Vehicle Speed Sensor The Vehicle Speed Sensor (VSS) is mounted to the automatic transaxle. The VSS provides a low voltage Alternating Current (AC) signal to the Powertrain Control Module (PCM). The PCM converts the AC signal to a pulse width modulated Direct Current (DC) signal. The DC signal is sent to the cruise control module at a rate of 4,000 pulses per mile. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Description and Operation > Page 12713 Cruise Control Module: Service and Repair REMOVAL PROCEDURE The cruise control module is mounted to the left strut tower and must be serviced as a complete unit. 1. Remove the cruise control cable from the cruise control module. 2. Remove the electrical connector from the cruise control module. 3. Remove the cruise control module shock tower nuts. 4. Remove the cruise control module. INSTALLATION PROCEDURE 1. Install the cruise control module on the mounting studs located on the shock tower. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Description and Operation > Page 12714 2. Install the cruise control module mounting nuts. Tighten Tighten the cruise control module mounting nuts to 2 N.m (18 lb in). 3. Install the electrical connector to the cruise control module. 4. Install the cruise control cable to the cruise control module. 5. Adjust the cruise control cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation Brake Switch (Cruise Control): Description and Operation The cruise control release switch and the stop lamp switch disengage the cruise control system. A cruise control release switch and a stop lamp switch are mounted on the brake pedal bracket. The switches disengage the system electrically when the brake pedal is pressed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations Cruise Control Switch: Component Locations Cruise Control ON/OFF Switch On the turn signal lever. On the steering wheel spoke. Cruise Control Release Switch Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations > Page 12723 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations > Page 12724 Locations View Behind the LH side of the instrument panel, on the brake pedal support. Cruise Control Resume/Accel Switch On the steering wheel spoke. Cruise Control Set/Cancel Switch On the steering wheel spoke. Cruise Control Steering Wheel Switch (LH) (SET/COAST) Lower Left side of steering wheel. Cruise Control Steering Wheel Switch (RH) (RESUME/ACCEL) Lower right side of steering wheel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations > Page 12725 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations > Page 12726 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations > Page 12727 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations > Page 12728 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions Cruise Control Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12731 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12732 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12733 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12734 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12735 Cruise Control Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12736 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12737 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12738 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12739 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12740 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12741 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12742 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12743 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12744 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12745 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12746 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12747 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12748 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12749 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12750 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12751 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12752 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12753 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12754 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12755 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12756 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12757 Cruise Control Release Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12758 Cruise Control Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Cruise Release Switch Replacement Cruise Control Switch: Service and Repair Cruise Release Switch Replacement REMOVAL PROCEDURE CAUTION: ^ Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components. ^ This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions: ^ Air bag deployment ^ Personal injury ^ Unnecessary SIR system repairs In order to avoid the above conditions, observe the following guidelines: ^ Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring. ^ If you are performing service on or near the SIR components or the SIR wiring, disable the SIR system. Refer to Disabling the SIR System in SIR. 1. Remove the driver side knee bolster panel. 2. Remove the electrical connector from the cruise control release switch. 3. Remove the cruise control release switch from the retainer in the brake pedal bracket. INSTALLATION PROCEDURE 1. Install the cruise control release switch to the retainer in the brake pedal bracket. 2. Install the electrical connector onto the cruise control release switch. 3. Adjust the cruise control release switch. 4. Install the driver side knee bolster panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Cruise Release Switch Replacement > Page 12761 Cruise Control Switch: Service and Repair Cruise Release Switch Adjustment IMPORTANT: The cruise control release switch and the stop lamp switch are adjusted together. Incorrect adjustment of either of these switches may cause premature brake lining wear or the cruise control system to not work properly. 1. Remove the left side insulator panel. 2. Press the brake pedal fully. 3. Push the switches into the retainers until the switches are fully seated. 4. Pull the brake pedal rearward against the pedal stop until the audible clicks can no longer be heard. 5. The following brake pedal travel distances can be used to validate the proper cruise control release switch and stop lamp switch adjustment. Cruise control release switch and the stop lamp switch contacts must actuate at 3.5 to 12.5 mm (1/8 to 1/2 in) of the brake pedal travel measured at the centerline of the brake pedal pad. Nominal actuation of the stop lamp switch contacts is about 4.5 mm (3/16 in) after the cruse control release switch actuation. 6. Install the left side insulator panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Testing and Inspection ABS Light: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Antilock Brakes / Traction Control Systems Testing and Inspection. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12770 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12771 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12772 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12773 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12774 Audible Warning Device: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12775 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12776 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12777 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12778 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12779 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12780 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12781 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12782 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12783 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12784 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12785 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12786 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12787 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12788 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12789 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12790 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12791 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12792 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12793 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12794 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 12795 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Testing and Inspection Brake Warning Indicator: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Hydraulic System Testing and Inspection. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Technical Service Bulletins > Customer Interest for Cigarette Lighter: > 99-08-45-005 > Nov > 99 > Accessory Receptacle/Cigar Lighter - Inoperative Cigarette Lighter: Customer Interest Accessory Receptacle/Cigar Lighter - Inoperative File In Section: 08 - Body and Accessories Bulletin No.: 99-08-45-005 Date: November, 1999 TECHNICAL Subject: Accessory Receptacle/Cigar Lighter is Inoperative (Check Aftermarket Device Plug for Short to Ground) Models: 1995-2000 Passenger Cars and Trucks Condition Some customers may comment that the cigar lighter or the accessory receptacle is inoperative; or that the internal fuse (within the plug on an aftermarket device), blows intermittently. Cause Certain aftermarket devices have a newly designed power plug with an internal mini fuse. The mini fuse may have an external terminal (which may be used to externally check the fuse). If the mini fuse external test terminal is not recessed into the mini fuse body, it may come in contact with the shell of the vehicle receptacle and cause the fuse (of either the vehicle or the aftermarket device), to blow intermittently. Correction Test the aftermarket device plug for short to ground. The following step may be performed at the customer's expense. As this is not a defect in material, design or workmanship of the vehicle, it would be the owner's responsibility. 1. Place a piece of tape over the mini fuse terminal temporarily. 2. Explain to the customer that the fuse for the device must have no exposed terminals, and that finding one would be his responsibility. 3. Refer the customer to the manufacturer of the aftermarket device for a new plug. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cigarette Lighter: > 99-08-45-005 > Nov > 99 > Accessory Receptacle/Cigar Lighter - Inoperative Cigarette Lighter: All Technical Service Bulletins Accessory Receptacle/Cigar Lighter - Inoperative File In Section: 08 - Body and Accessories Bulletin No.: 99-08-45-005 Date: November, 1999 TECHNICAL Subject: Accessory Receptacle/Cigar Lighter is Inoperative (Check Aftermarket Device Plug for Short to Ground) Models: 1995-2000 Passenger Cars and Trucks Condition Some customers may comment that the cigar lighter or the accessory receptacle is inoperative; or that the internal fuse (within the plug on an aftermarket device), blows intermittently. Cause Certain aftermarket devices have a newly designed power plug with an internal mini fuse. The mini fuse may have an external terminal (which may be used to externally check the fuse). If the mini fuse external test terminal is not recessed into the mini fuse body, it may come in contact with the shell of the vehicle receptacle and cause the fuse (of either the vehicle or the aftermarket device), to blow intermittently. Correction Test the aftermarket device plug for short to ground. The following step may be performed at the customer's expense. As this is not a defect in material, design or workmanship of the vehicle, it would be the owner's responsibility. 1. Place a piece of tape over the mini fuse terminal temporarily. 2. Explain to the customer that the fuse for the device must have no exposed terminals, and that finding one would be his responsibility. 3. Refer the customer to the manufacturer of the aftermarket device for a new plug. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Locations > Component Locations Cigarette Lighter: Component Locations Cigar Lighter (W/ Console) Center console, forward of the transaxle selector Cigar Lighter (W/O Center Console) Locations View RPO W/O D55: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Cigar Lighter (W/O Console) In ashtray assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Locations > Component Locations > Page 12814 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12817 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12818 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12819 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12820 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12821 Cigarette Lighter: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12822 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12823 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12824 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12825 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12826 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12827 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12828 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12829 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12830 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12831 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12832 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12833 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12834 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12835 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12836 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12837 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12838 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12839 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12840 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12841 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12842 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12843 Cigarette Lighter: Connector Views Cigar Lighter 2 Door (W/ RPO D55) Cigar Lighter 2 Door RPO D55: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Cigar Lighter 4 Door (W/ RPO D55) Cigar Lighter 4 Door RPO D55: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Cigar Lighter 4 Door (W/O RPO D55) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12844 Cigar Lighter 4 Door RPO D55: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 12845 Cigar Lighter/Auxiliary Outlets Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 12846 Cigarette Lighter: Description and Operation CIGAR LIGHTER Voltage is applied at all times to the cigar lighter through the CIG/LTR fuse in the RH IP Accessory Wiring Junction Block and the cigar lighter feed circuit. The cigar lighter has a heating element. Pushing the cigar lighter all of the way into the mounting completes the circuit to ground through the cigar lighter ground and heats the cigar lighter heating element. When the element is sufficiently heated, the cigar lighter is released from the mounting through thermal expansion of the mounting and the circuit is opened. AUXILIARY POWER OUTLET An auxiliary power outlet is provided adjacent to the cigar lighter to power customer owned and maintained equipment. Voltage is applied at all times to the auxiliary outlet through the AUX Power fuse in the RH IP Accessory Wiring Junction Block and the auxiliary power feed circuit. A ground circuit is also provided as a portion of this same outlet AUXILIARY POWER DROP CONNECTOR An auxiliary power drop connector is also provided for the installation of various types of accessories that require a more permanent type of connection. The connector, located under the right hand side of the IP, contains two B+ circuits - one supplied from the CIG/AUX fuse in the LH IP Accessory Wiring Junction Block and the other is supplied through the PWR Drop fuse in the RH IP Accessory Wiring Junction Block. A ground circuit is provided through ground G 201. A serial data communications circuit is also provided for equipment that requires the capability to communicate with control modules on the vehicle. Voltage is supplied when the ignition switch is in ACCY or Run through the CIG/AUX fuse in the LH IP Accessory Wiring Junction Block. Voltage is applied at all times to the auxiliary power drop connector through the PWR DROP fuse in the RH IP Accessory Wiring Junction Block. Ground is also supplied to the auxiliary power drop connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Testing and Inspection > A Diagnostic Starting Point Cigarette Lighter: Testing and Inspection A Diagnostic Starting Point Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms in order to identify the correct procedure for diagnosing the system and where the procedure is located. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Testing and Inspection > A Diagnostic Starting Point > Page 12849 Cigarette Lighter: Testing and Inspection Symptoms IMPORTANT: Review the system operation in order to familiarize yourself with the system functions. Refer to Cigar Lighter/Auxiliary Outlet Circuit Description Visual/Physical Inspection ^ Inspect for aftermarket devices which could affect the operation of the cigar lighter and auxiliary outlets. Refer to Checking Aftermarket Accessories in Diagrams. ^ Inspect the cigar lighter and easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent and Poor Connections in Diagrams. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: ^ Cigar Lighter Inoperative ^ Auxiliary Outlets Inoperative Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Testing and Inspection > A Diagnostic Starting Point > Page 12850 Cigarette Lighter: Testing and Inspection Cigar Lighter Inoperative Diagnostic Chart (Part 1 Of 2) Diagnostic Chart (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Testing and Inspection > Page 12851 Cigarette Lighter: Service and Repair Cigarette Lighter Replacement - IP REMOVAL PROCEDURE TOOLS REQUIRED J 42059 Cigarette Lighter Socket Remover 1. Remove the cigarette lighter fuse. 2. Remove the cigarette lighter element. 3. Remove the cigarette lighter socket by placing one side of the "T" portion of the tool J 42059 into the tab window and then the other should be angled into the opposite tab window, then pull the lighter socket straight out. 4. Remove the tool from the lighter socket. 5. Disconnect the electrical connector from the cigarette lighter socket. INSTALLATION PROCEDURE 1. Connect the electrical connector to cigarette lighter socket. 2. Align the cigarette lighter socket to the instrument panel and press into place until fully seated. 3. Install the cigarette lighter fuse. 4. Install the cigarette lighter element. 5. Inspect the instrument panel lighter for proper operation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair Compass: Service and Repair Electronic Compass Calibration The electronic compass is capable of distinguishing 8 primary directions: ^ North (N) ^ Northeast (NE) ^ East (E) ^ Southeast (SE) ^ South (S) ^ Southwest (SW) ^ West (W) ^ Northwest (NW) The compass calibration procedures establish a base direction from which the compass can work. Once the compass has been properly calibrated, the digital display indicates the direction of vehicle travel. Calibration Procedure The compass is self-calibrating, eliminating the need to manually set the compass. Occasionally, the calibration process on a new vehicle may not be complete, causing the CAL symbol to illuminate. In order to correct this problem, drive the vehicle less than 5 mph (8 km/h) through 3 complete 360 degree turns. The CAL symbol will then turn OFF and the compass will function normally. If the compass appears erratic and the CAL symbol does not appear, you must manually put the compass into the calibration mode. 1. Turn ON the ignition. 2. Press the MODE button until the compass/temperature mode appears. 3. Press and hold the RESET button on the overhead console for approximately 10 seconds, or until the display reads CAL. 4. Release the RESET button and drive the vehicle less than 5 mph (8 km/h) through 3 complete 360 degree turns. The CAL symbol will turn off when the compass is calibrated, and the compass will function normally. Variance Variance is defined as the difference between magnetic north and geographic north. In some areas of the country, this difference is great enough to cause false compass readings. Set the variance for a particular location as follows: 1. Determine the vehicle's location on the zone map. Note the zone number. 2. Turn ON the ignition. 3. Press the MODE button until the compass/temperature mode appears. 4. Press and hold the RESET button on the overhead console for approximately 5 seconds. The last entered variance zone appears on the display. 5. Press the MODE button until the correct zone number appears on the display. 6. Press the RESET button in order to set the new variance zone and resume normal operation. The display will illuminate all segments briefly in order to acknowledge the change in the zone number. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions Coolant Level Indicator Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12860 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12861 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12862 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12863 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12864 Coolant Level Indicator Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12865 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12866 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12867 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12868 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12869 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12870 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12871 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12872 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12873 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12874 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12875 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12876 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12877 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12878 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12879 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12880 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12881 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12882 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12883 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12884 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12885 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Module > Component Information > Diagrams > Page 12886 Coolant Level Indicator Module: Service and Repair Removal Procedure 1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 2. Partially drain the radiator. Refer to Draining and Filling Cooling System. 3. Disconnect the low coolant module electrical connector. 4. In order to unlock the low coolant module, lift one leg of the snap clip from its locked position and pull outward with a slight twisting motion. Remove the low coolant module. Installation Procedure 1. Lubricate the O-ring seal with coolant. 2. Position the snap clip leg in place. 3. Install the low coolant module. 4. Connect the low coolant module electrical connector. 5. Fill the radiator. Refer to Draining and Filling Cooling System. 6. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 7. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions CAUTION: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserve energy supply. The reserve energy supply provides deployment power for the air bags. Deployment power is available for as much as 10 seconds after disconnecting the vehicle power by any of the following methods: ^ Turn OFF the ignition. ^ Remove the fuse that provides power to the SDM. ^ Disconnect the vehicle battery from the vehicle electrical system. Disabling the SIR system prevents deploying of the air bags from the reserve energy supply power. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the LH instrument panel access hole cover. 5. Remove the SDM Fuse from the fuse block. IMPORTANT: With the SDM Fuse removed and the ignition ON, The AIR BAG warning lamp illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the RH instrument panel access hole cover. 7. Unclip the frontal air bags yellow 4-way connector from the metal rail. 8. Remove the Connector Position Assurance (CPA) from the frontal air bags yellow 4-way connector. 9. Disconnect the frontal air bags yellow 4-way connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 12893 10. Remove the connector position assurance (CPA) from the driver side air bag yellow 2-way connector (4) located under the driver seat, if the vehicle is equipped with a driver side air bag. 11. Disconnect the driver side air bag yellow 2-way connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 12894 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Connect the driver side air bag yellow 2-way connector (4) located under the driver seat, if the vehicle is equipped with a driver side air bag. 2. Install the CPA to the driver side air bag yellow 2-way connector. 3. Connect the frontal air bags yellow 4-way connector located at the RH side of the instrument panel. 4. Install the CPA to the frontal air bags yellow 4-way connector. 5. Connect the frontal air bags yellow 4-way connector to the metal rail. 6. Instal the RH instrument panel access hole cover. 7. Install the SDM fuse to the LH fuse block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 12895 8. Install the LH instrument panel access hole cover. 9. Staying well away from the airbags, turn ON the ignition. 9.1. The AIR BAG warning lamp will flash seven times. 9.2. The AIR BAG warning lamp will then turn OFF. 10. Perform A Diagnostic System Check SIR if the AIR BAG warning lamp does not operate as described. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Technical Service Bulletins > IP Dimmer Control - Proper Setting Dimmer Switch: Technical Service Bulletins IP Dimmer Control - Proper Setting File In Section: 08 - Body and Accessories Bulletin No.: 99-08-42-009 Date: November, 1999 INFORMATION Subject: Proper Setting of I/P Dimmer Control to View PRNDL Display with Automatic Headlamp Control Models: 2000 and Prior All Passenger Cars and Trucks With Automatic Headlamp Control and Electronic PRNDL Display Under certain conditions, if the instrument panel dimmer control is turned relatively low, the PRNDL will not be visible until the automatic headlamp control turns the headlamps off and the daytime running lamps (DRL) are turned back on. Such a condition may be if the vehicle is first started in an environment where the headlamp control turns on the headlamps and then the vehicle is driven out into a brighter environment (for example, when a vehicle is backed out of a dark garage into the bright sunlight). This condition is normal and any repair attempt will not be successful. Demonstrate this condition to the customer using the service lane and then turn the instrument panel dimmer control to a higher setting. This will enable the driver to see the PRNDL display Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Technical Service Bulletins > Page 12900 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > LF Door Ajar Switch Indicator, C1 LF Door Ajar Switch Indicator, C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > LF Door Ajar Switch Indicator, C1 > Page 12906 LR Door Ajar Switch Indicator, C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > LF Door Ajar Switch Indicator, C1 > Page 12907 RF Door Ajar Switch Indicator, C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > LF Door Ajar Switch Indicator, C1 > Page 12908 RR Door Ajar Switch Indicator, C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > DID Digital Display Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > DID Digital Display > Page 12913 Driver/Vehicle Information Display: Locations Driver Information Display Control Module In the front center of the roof headliner. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12916 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12917 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12918 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12919 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12920 Driver/Vehicle Information Display: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12921 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12922 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12923 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12924 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12925 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12926 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12927 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12928 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12929 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12930 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12931 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12932 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12933 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12934 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12935 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12936 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12937 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12938 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12939 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12940 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 12941 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Mounted in the fuel tank. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12947 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12948 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12949 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12950 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12951 Fuel Gauge Sender: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12952 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12953 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12954 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12955 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12956 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12957 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12958 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12959 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12960 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12961 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12962 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12963 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12964 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12965 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12966 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12967 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12968 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12969 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12970 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12971 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12972 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 12973 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Page 12974 Fuel Gauge Sender: Description and Operation The fuel level sensor consists of the following components: float, the wire float arm, and the ceramic resistor card. The fuel level sensor is mounted on the modular fuel sender assembly and is used as an input to the PCM. The PCM uses this information as a fuel level input for Various diagnostics. In addition the PCM transmits the fuel level over the Class II communication circuit to the IP cluster. This information is used for the IP fuel gauge, and low fuel warning indicator if applicable. Fuel Level Sensor The Fuel Level Sensor(4) is mounted on the Modular Fuel Sender Assembly(s). The PCM uses the fuel level input for various diagnosis including the EVAP System. In addition the PCM transmits the fuel level over the Class II communication circuit to the IP Cluster. The low fuel level message may not appear if other messages are being commanded, such as the rear deck lid, driver or passenger doors ajar. Ensure that all doors and compartment lids are completely closed. For further information regarding the Fuel Level Sensor refer to Fuel Metering Modes of Operation. See: Powertrain Management/Fuel Delivery and Air Induction/Description and Operation/Fuel Metering/Fuel Metering Modes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Page 12975 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure. See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 2. Remove the modular fuel sender assembly. 3. Remove the fuel level sensor (5) from the modular fuel sender. INSTALLATION PROCEDURE 1. Reinstall the fuel level sensor (5) to modular fuel sender. 2. Reinstall the fuel sender assembly. 3. Tighten the fuel filler cap. 4. Reconnect the negative battery cable. 5. Inspect for fuel leaks. 5.1. Turn the ignition ON for 2 seconds 5.2. Turn the ignition OFF for 10 seconds. 5.3. Turn the ignition ON. 5.4. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions CAUTION: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserve energy supply. The reserve energy supply provides deployment power for the air bags. Deployment power is available for as much as 10 seconds after disconnecting the vehicle power by any of the following methods: ^ Turn OFF the ignition. ^ Remove the fuse that provides power to the SDM. ^ Disconnect the vehicle battery from the vehicle electrical system. Disabling the SIR system prevents deploying of the air bags from the reserve energy supply power. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the LH instrument panel access hole cover. 5. Remove the SDM Fuse from the fuse block. IMPORTANT: With the SDM Fuse removed and the ignition ON, The AIR BAG warning lamp illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the RH instrument panel access hole cover. 7. Unclip the frontal air bags yellow 4-way connector from the metal rail. 8. Remove the Connector Position Assurance (CPA) from the frontal air bags yellow 4-way connector. 9. Disconnect the frontal air bags yellow 4-way connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 12982 10. Remove the connector position assurance (CPA) from the driver side air bag yellow 2-way connector (4) located under the driver seat, if the vehicle is equipped with a driver side air bag. 11. Disconnect the driver side air bag yellow 2-way connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 12983 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Connect the driver side air bag yellow 2-way connector (4) located under the driver seat, if the vehicle is equipped with a driver side air bag. 2. Install the CPA to the driver side air bag yellow 2-way connector. 3. Connect the frontal air bags yellow 4-way connector located at the RH side of the instrument panel. 4. Install the CPA to the frontal air bags yellow 4-way connector. 5. Connect the frontal air bags yellow 4-way connector to the metal rail. 6. Instal the RH instrument panel access hole cover. 7. Install the SDM fuse to the LH fuse block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 12984 8. Install the LH instrument panel access hole cover. 9. Staying well away from the airbags, turn ON the ignition. 9.1. The AIR BAG warning lamp will flash seven times. 9.2. The AIR BAG warning lamp will then turn OFF. 10. Perform A Diagnostic System Check SIR if the AIR BAG warning lamp does not operate as described. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Locations Low Tire Pressure Indicator: Locations Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Locations > Page 12988 Component Locator Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions Low Tire Pressure Indicator: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 12991 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 12992 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 12993 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 12994 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 12995 Low Tire Pressure Indicator: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 12996 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 12997 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 12998 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 12999 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13000 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13001 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13002 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13003 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13004 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13005 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13006 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13007 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13008 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13009 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13010 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13011 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13012 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13013 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13014 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13015 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13016 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13017 Low Tire Pressure Indicator: Electrical Diagrams Schematic and Routing Diagrams Tire Pressure Monitoring System Schematics (EBCM, Power, Ground and Instrument Cluster) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13018 Tire Pressure Monitoring System Schematics (Wheel Speed Sensors) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13019 Tire Pressure Monitoring System Schematics: EBCM, Power, Ground And Instrument Cluster Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13020 Tire Pressure Monitoring System Schematics: Wheel Speed Sensors Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation > Low Tire Pressure Warning System (LTPWS) Low Tire Pressure Indicator: Description and Operation Low Tire Pressure Warning System (LTPWS) Tire Inflation Monitoring System Operation The tire pressure monitor (TPM) system alerts the driver when the pressure changes in one of the tires. The system only detects a low pressure condition while the vehicle is being driven. Once a low tire pressure condition is detected, the system informs the driver whenever the ignition is ON. The LOW TIRE PRESSURE indicator illuminates if the tire pressure in one or more tires become at least 52 kPa (12 psi) lower or higher than the other tires. The message does not appear if the system is not calibrated properly. The system does not inform the driver which tire is low. To clear this message., set the tire pressures in all four tires to the proper pressures and perform the system reset procedure. Refer to Tire Inflation Monitor Reset Procedure for service procedure. See: Tire Monitoring System/Testing and Inspection The Tire Pressure Monitor software requires approximately One half hour of straight line driving to complete the TPM autolearn. There 'are several speed ranges' that the EBCM needs to learn the tire inflation configuration in order to have the full capability of detecting a low tire condition. The speed detection ranges are the following: ^ 24~64 km/h (15-40 mph) ^ 64-113km/h (40-70 mph) ^ 113-145 km/h (7O~90 mph) Each speed range has 2 modes of low tire detection. ^ Monitor Mode 1 ^ Monitor Mode 2 The, EBCM learns the tire inflation configuration for each speed range independently. In Monitor Mode 1, the EBCM has only partially learned the tire inflation configuration for the speed range and has limited detection capability for a low tire condition. In Monitor Mode 2, the EBCM has fully learned the tire inflation configuration for the speed range and has full detection capability for a low tire condition. If the EBCM is not in Monitor Mode 1 or Monitor Mode 2, a low tire condition cannot be detected because the EBCM has not learned the tire inflation configuration of the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation > Low Tire Pressure Warning System (LTPWS) > Page 13023 Low Tire Pressure Indicator: Description and Operation Tire Inflation Monitoring System Operation The tire pressure monitor (TPM) system alerts the driver when the pressure changes in one of the tires. The system only detects a low pressure condition while the vehicle is being driven. Once a low tire pressure condition is detected, the system informs the driver whenever the ignition is ON. The LOW TIRE PRESSURE indicator illuminates if the tire pressure in one or more tires become at least 82 kPa (12 psi) lower or higher than the other tires. The message does not appear if the system is not calibrated properly. The system does not inform the driver which tire is low. To clear this message, set the tire pressures in all four tires to the proper pressures and perform the system reset procedure. Refer to Tire Inflation Monitor Reset Procedure for service procedure. The Tire Pressure Monitor software requires approximately one half hour of straight line driving to complete the TPM auto-learn. There are several speed ranges that the EBCM needs to learn the tire inflation configuration in order to have the full capability of detecting a low tire condition. The speed detection ranges are the following: ^ 24-64 km/h (15-40 mph) ^ 64-113 km/h (40-70 mph) ^ 113-145 km/h (70-90 mph) Each speed range has 2 modes of low tire detection. ^ Monitor Mode 1 ^ Monitor Mode 2 The EBCM learns the tire inflation configuration for each speed range independently. In Monitor Mode 1, the EBCM has only partially learned the tire inflation configuration for the speed range and has limited detection capability for a low tire condition. In Monitor Mode 2, the EBCM has fully learned the tire inflation configuration for the speed range and has full detection capability for a low tire condition. If the EBCM is not in Monitor Mode 1 or Monitor Mode 2, a low tire condition cannot be detected because the EBCM has not learned the tire inflation configuration of the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Malfunction Indicator Lamp: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13028 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13029 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13030 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13031 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13032 Malfunction Indicator Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13033 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13034 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13035 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13036 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13037 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13038 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13039 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13040 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13041 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13042 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13043 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13044 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13045 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13046 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13047 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13048 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13049 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13050 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13051 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13052 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13053 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13054 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Malfunction Indicator Lamp (MIL) - Description Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) Description The Service Engine Soon/Malfunction Indicator Lamp (MIL) is located in the Instrument Panel (IP) Cluster. The MIL is controlled by the PCM and is used to indicate that the PCM has detected a condition that affects vehicle emissions, may cause powertrain damage, or severely impacts driveability. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Malfunction Indicator Lamp (MIL) - Description > Page 13057 Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) Operation The Malfunction Indicator Lamp (MIL) is located on the instrument panel and is displayed as CHECK ENGINE lamp. MIL Function ^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible ^ The MIL illuminates during a bulb test and a system test ^ A DTC will be stored if a MIL is requested by the diagnostic MIL Illumination ^ The MIL will illuminate with ignition ON and the engine OFF ^ The MIL will turn OFF when the engine is started ^ The MIL will remain ON if the self-diagnostic system has detected a malfunction ^ The MIL may turn OFF if the malfunction is not present ^ If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. ^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 13058 Malfunction Indicator Lamp: Service and Repair SERVICE ENGINE SOON INDICATOR If this light is on, it indicates a problem in one of the electronically monitored systems. This light does NOT come on at certain mileage intervals. There is probably a Engine Control Module (ECM) or a Body Control Module (BCM) Code set that will aid you in diagnosis. Reset Procedure The only way to get the light to go off is to clear the ECM or BCM code(s). This light can NOT be reset or shut off any other way. ECM/BCM codes should be read & repaired before clearing them. SERVICE VEHICLE SOON INDICATOR If this light is on, it indicates a problem in one of the electronically monitored systems (a non-emissions related powertrain malfunction). This light does NOT come on at certain mileage intervals. There is probably a Engine Control Module (ECM) or a Body Control Module (BCM) Code set that will aid you in diagnosis. Reset Procedure The only way to get the light to go off is to clear the ECM or BCM code(s). This light can NOT be reset or shut off any other way. ECM/BCM codes should be read & repaired before clearing them. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation Oil Change Reminder Lamp: Description and Operation GM OIL LIFE SYSTEM If the vehicle is equipped with a GM Oil Life System, this feature will let you know when to change the oil and filter - usually between 3,000 miles (5 000 km) and 7,500 miles (12 500 km) since your last oil change. Under severe conditions, the indicator may come on before 3,000 miles (5 000 km). Never drive the vehicle more than 12 500 km (7,500 miles) or 12 months, (whichever occurs first), without an oil change. The GM Oil Life System will not detect dust in the oil. If the vehicle is driven in a dusty area, be sure to change the oil every 5 000 km (3,000 miles) or sooner if the "CHANGE OIL" or "CHANGE OIL SOON" message is displayed. To reset the GM Oil Life System, refer to Service and Repair. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 13062 Oil Change Reminder Lamp: Service and Repair GM Oil Life System Resetting Resetting Procedure Follow this procedure to reset the GM Oil Life System (TM) 1. Turn the ignition to ON without starting the engine. 2. Fully press and release the accelerator pedal three times within five seconds. If the CHG OIL SOON indicator flashes two times, the system is resetting. 3. Turn the key to OFF, then start the vehicle. If the CHG OIL SOON light comes back on, the system has not reset, repeat the procedure Follow this procedure to reset the GM Oil Life System (TM) using the DE 100 Series Radio (R) 1. Turn the ignition to ACC or ON and the radio off. 2. Press and hold the DISP button on the radio for at least five seconds until SETTINGS is displayed. 3. Press the SEEK up or down arrow to scroll though the main menu 4. Scroll until OIL LIFE appears on the display. 5. Press the PREV or NEXT button to enter the submenu. RESET will be displayed. 6. Press the DISP button to reset. A chime will be heard to verify the new setting and DONE will be displayed for one second. 7. Once the message has been reset, scroll until EXIT appears on the display. 8. Press the DISP button to exit programming. A chime will be heard to verify the exit. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Description and Operation Oil Level Warning Indicator: Description and Operation Engine Oil Level Switch The PCM monitors the engine oil level switch signal at start-up to determine if the engine oil is OK. If the PCM determines that a low oil level condition exists, the PCM will communicate the information over the Class II circuit to the P cluster and it will illuminate the indicator lamp or initiate a message. The low oil level message may not appear if other messages are being commanded, such as the rear deck lid, driver or passenger doors ajar. Ensure that all doors and compartment lids are completely closed. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Engine Oil Pressure Indicator Switch 115 in.lb Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 13069 Engine Oil Pressure Indicator Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Specifications Parking Brake Warning Switch: Specifications Park Brake Indicator Switch Mounting Screw ..................................................................................................................................................... 26 inch lbs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Specifications > Page 13073 Parking Brake Warning Switch: Service and Repair Removal Procedure 1. Remove the left side instrument panel insulator. Refer to Insulator Replacement - IP (Left) in Instrument Panel, Gauges and Warning Indicators. 2. Remove the left carpet retainer and pull carpet back. Refer to Carpet Retainer Replacement (Impala) or Carpet Retainer Replacement (Monte Carlo) 3. Disconnect the electrical connector from the switch. 4. Remove the mounting screw. 5. Remove the parking brake indicator switch (1). Installation Procedure 1. Install the parking brake indicator switch (1). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the mounting screw. ^ Tighten the mounting screw to 3 Nm (26 inch lbs.). 3. Connect the electrical connector to the switch. Check the operation of the switch. 4. Install the left carpet retainer and carpet. Refer to Carpet Retainer Replacement (Impala) or Carpet Retainer Replacement (Monte Carlo). 5. Install the left side instrument panel insulator. Refer to Insulator Replacement - IP (Left) in Instrument Panel, Gauges and Warning Indicators. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions Coolant Level Indicator Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13080 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13081 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13082 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13083 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13084 Coolant Level Indicator Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13085 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13086 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13087 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13088 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13089 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13090 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13091 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13092 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13093 ^ Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13094 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13095 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13096 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13097 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13098 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13099 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13100 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13101 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13102 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13103 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13104 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13105 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Coolant Level Indicator Module > Component Information > Diagrams > Page 13106 Coolant Level Indicator Module: Service and Repair Removal Procedure 1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 2. Partially drain the radiator. Refer to Draining and Filling Cooling System. 3. Disconnect the low coolant module electrical connector. 4. In order to unlock the low coolant module, lift one leg of the snap clip from its locked position and pull outward with a slight twisting motion. Remove the low coolant module. Installation Procedure 1. Lubricate the O-ring seal with coolant. 2. Position the snap clip leg in place. 3. Install the low coolant module. 4. Connect the low coolant module electrical connector. 5. Fill the radiator. Refer to Draining and Filling Cooling System. 6. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging. 7. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Technical Service Bulletins > IP Dimmer Control - Proper Setting Dimmer Switch: Technical Service Bulletins IP Dimmer Control - Proper Setting File In Section: 08 - Body and Accessories Bulletin No.: 99-08-42-009 Date: November, 1999 INFORMATION Subject: Proper Setting of I/P Dimmer Control to View PRNDL Display with Automatic Headlamp Control Models: 2000 and Prior All Passenger Cars and Trucks With Automatic Headlamp Control and Electronic PRNDL Display Under certain conditions, if the instrument panel dimmer control is turned relatively low, the PRNDL will not be visible until the automatic headlamp control turns the headlamps off and the daytime running lamps (DRL) are turned back on. Such a condition may be if the vehicle is first started in an environment where the headlamp control turns on the headlamps and then the vehicle is driven out into a brighter environment (for example, when a vehicle is backed out of a dark garage into the bright sunlight). This condition is normal and any repair attempt will not be successful. Demonstrate this condition to the customer using the service lane and then turn the instrument panel dimmer control to a higher setting. This will enable the driver to see the PRNDL display Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Technical Service Bulletins > Page 13112 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Mounted in the fuel tank. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13118 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13119 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13120 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13121 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13122 Fuel Gauge Sender: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13123 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13124 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13125 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13126 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13127 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13128 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13129 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13130 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13131 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13132 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13133 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13134 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13135 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13136 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13137 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13138 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13139 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13140 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13141 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13142 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13143 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 13144 Schematic Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 13145 Fuel Gauge Sender: Description and Operation The fuel level sensor consists of the following components: float, the wire float arm, and the ceramic resistor card. The fuel level sensor is mounted on the modular fuel sender assembly and is used as an input to the PCM. The PCM uses this information as a fuel level input for Various diagnostics. In addition the PCM transmits the fuel level over the Class II communication circuit to the IP cluster. This information is used for the IP fuel gauge, and low fuel warning indicator if applicable. Fuel Level Sensor The Fuel Level Sensor(4) is mounted on the Modular Fuel Sender Assembly(s). The PCM uses the fuel level input for various diagnosis including the EVAP System. In addition the PCM transmits the fuel level over the Class II communication circuit to the IP Cluster. The low fuel level message may not appear if other messages are being commanded, such as the rear deck lid, driver or passenger doors ajar. Ensure that all doors and compartment lids are completely closed. For further information regarding the Fuel Level Sensor refer to Fuel Metering Modes of Operation. See: Powertrain Management/Fuel Delivery and Air Induction/Description and Operation/Fuel Metering/Fuel Metering Modes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 13146 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure. See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 2. Remove the modular fuel sender assembly. 3. Remove the fuel level sensor (5) from the modular fuel sender. INSTALLATION PROCEDURE 1. Reinstall the fuel level sensor (5) to modular fuel sender. 2. Reinstall the fuel sender assembly. 3. Tighten the fuel filler cap. 4. Reconnect the negative battery cable. 5. Inspect for fuel leaks. 5.1. Turn the ignition ON for 2 seconds 5.2. Turn the ignition OFF for 10 seconds. 5.3. Turn the ignition ON. 5.4. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Specifications Parking Brake Warning Switch: Specifications Park Brake Indicator Switch Mounting Screw ..................................................................................................................................................... 26 inch lbs. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Specifications > Page 13150 Parking Brake Warning Switch: Service and Repair Removal Procedure 1. Remove the left side instrument panel insulator. Refer to Insulator Replacement - IP (Left) in Instrument Panel, Gauges and Warning Indicators. 2. Remove the left carpet retainer and pull carpet back. Refer to Carpet Retainer Replacement (Impala) or Carpet Retainer Replacement (Monte Carlo) 3. Disconnect the electrical connector from the switch. 4. Remove the mounting screw. 5. Remove the parking brake indicator switch (1). Installation Procedure 1. Install the parking brake indicator switch (1). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the mounting screw. ^ Tighten the mounting screw to 3 Nm (26 inch lbs.). 3. Connect the electrical connector to the switch. Check the operation of the switch. 4. Install the left carpet retainer and carpet. Refer to Carpet Retainer Replacement (Impala) or Carpet Retainer Replacement (Monte Carlo). 5. Install the left side instrument panel insulator. Refer to Insulator Replacement - IP (Left) in Instrument Panel, Gauges and Warning Indicators. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Locations Low Tire Pressure Indicator: Locations Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Locations > Page 13155 Component Locator Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions Low Tire Pressure Indicator: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13158 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13159 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13160 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13161 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13162 Low Tire Pressure Indicator: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13163 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13164 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13165 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13166 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13167 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13168 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13169 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13170 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13171 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13172 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13173 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13174 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13175 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13176 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13177 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13178 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13179 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13180 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13181 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13182 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13183 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13184 Low Tire Pressure Indicator: Electrical Diagrams Schematic and Routing Diagrams Tire Pressure Monitoring System Schematics (EBCM, Power, Ground and Instrument Cluster) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13185 Tire Pressure Monitoring System Schematics (Wheel Speed Sensors) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13186 Tire Pressure Monitoring System Schematics: EBCM, Power, Ground And Instrument Cluster Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 13187 Tire Pressure Monitoring System Schematics: Wheel Speed Sensors Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Low Tire Pressure Warning System (LTPWS) Low Tire Pressure Indicator: Description and Operation Low Tire Pressure Warning System (LTPWS) Tire Inflation Monitoring System Operation The tire pressure monitor (TPM) system alerts the driver when the pressure changes in one of the tires. The system only detects a low pressure condition while the vehicle is being driven. Once a low tire pressure condition is detected, the system informs the driver whenever the ignition is ON. The LOW TIRE PRESSURE indicator illuminates if the tire pressure in one or more tires become at least 52 kPa (12 psi) lower or higher than the other tires. The message does not appear if the system is not calibrated properly. The system does not inform the driver which tire is low. To clear this message., set the tire pressures in all four tires to the proper pressures and perform the system reset procedure. Refer to Tire Inflation Monitor Reset Procedure for service procedure. See: Testing and Inspection The Tire Pressure Monitor software requires approximately One half hour of straight line driving to complete the TPM autolearn. There 'are several speed ranges' that the EBCM needs to learn the tire inflation configuration in order to have the full capability of detecting a low tire condition. The speed detection ranges are the following: ^ 24~64 km/h (15-40 mph) ^ 64-113km/h (40-70 mph) ^ 113-145 km/h (7O~90 mph) Each speed range has 2 modes of low tire detection. ^ Monitor Mode 1 ^ Monitor Mode 2 The, EBCM learns the tire inflation configuration for each speed range independently. In Monitor Mode 1, the EBCM has only partially learned the tire inflation configuration for the speed range and has limited detection capability for a low tire condition. In Monitor Mode 2, the EBCM has fully learned the tire inflation configuration for the speed range and has full detection capability for a low tire condition. If the EBCM is not in Monitor Mode 1 or Monitor Mode 2, a low tire condition cannot be detected because the EBCM has not learned the tire inflation configuration of the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Low Tire Pressure Warning System (LTPWS) > Page 13190 Low Tire Pressure Indicator: Description and Operation Tire Inflation Monitoring System Operation The tire pressure monitor (TPM) system alerts the driver when the pressure changes in one of the tires. The system only detects a low pressure condition while the vehicle is being driven. Once a low tire pressure condition is detected, the system informs the driver whenever the ignition is ON. The LOW TIRE PRESSURE indicator illuminates if the tire pressure in one or more tires become at least 82 kPa (12 psi) lower or higher than the other tires. The message does not appear if the system is not calibrated properly. The system does not inform the driver which tire is low. To clear this message, set the tire pressures in all four tires to the proper pressures and perform the system reset procedure. Refer to Tire Inflation Monitor Reset Procedure for service procedure. The Tire Pressure Monitor software requires approximately one half hour of straight line driving to complete the TPM auto-learn. There are several speed ranges that the EBCM needs to learn the tire inflation configuration in order to have the full capability of detecting a low tire condition. The speed detection ranges are the following: ^ 24-64 km/h (15-40 mph) ^ 64-113 km/h (40-70 mph) ^ 113-145 km/h (70-90 mph) Each speed range has 2 modes of low tire detection. ^ Monitor Mode 1 ^ Monitor Mode 2 The EBCM learns the tire inflation configuration for each speed range independently. In Monitor Mode 1, the EBCM has only partially learned the tire inflation configuration for the speed range and has limited detection capability for a low tire condition. In Monitor Mode 2, the EBCM has fully learned the tire inflation configuration for the speed range and has full detection capability for a low tire condition. If the EBCM is not in Monitor Mode 1 or Monitor Mode 2, a low tire condition cannot be detected because the EBCM has not learned the tire inflation configuration of the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Testing and Inspection Traction Control Indicator Lamp: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Antilock Brakes / Traction Control Systems Testing and Inspection. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Technical Service Bulletins > Instruments - Reduced PRNDL Display Visibility Transmission Shift Position Indicator Lamp: Technical Service Bulletins Instruments - Reduced PRNDL Display Visibility Bulletin No.: 02-08-42-004A Date: March 30, 2007 INFORMATION Subject: PRNDL Display Reduced Visibility For Approximately One Minute Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Headlamp Control and Vacuum Fluorescent PRNDL Indicator Instrument Panel Cluster Supercede: This bulletin is being revised to include additional models and model years. Please discard Corporate Bulletin Number 02-08-42-0004 (Section 08 - Body and Accessories). After backing the vehicle out of a garage or dark environment into a daylight environment, the PRNDL display has reduced visibility for approximately one minute. While the vehicle is parked in a dark environment, the sensor for the automatic headlamp/driving lamps senses that it is dark. When the key is turned to the run/start position, the automatic headlamp module will turn all driving lamps, the instrument panel cluster and PRNDL display ON in the night-time mode. The night-time mode intensity of the instrument panel lamps and PRNDL display is controlled by the automatic headlamp module and can be dimmed further by the customer using the dimming control of the headlamp switch. When the customer then moves the vehicle from the dark environment into the bright sunlight, it will take approximately one minute before the headlamp control module recognizes this as true daylight and not just a bright overhead street lamp shining on the sensor. The headlamp control module will then turn the headlamps off and restore the instrument panel and PRNDL display to full brilliance. Without the time delay, the automatic headlamp control module would switch to the night mode (turn on all driving lamps, instrument panel lamps and PRNDL display would dim) each time the vehicle was driven under an overpass or other darkened environment. This is a normal condition and no repair should be attempted. Ensure the instrument panel backlighting control is in the full bright position. This will help alleviate the condition. You may demonstrate to the customer what happens by placing a repair order over the automatic headlamp control light sensor, which will cause the automatic headlamp control module to switch to the night mode in approximately one minute. All driving lamps will come ON, the instrument panel backlight will be dim, and the PRNDL display will also dim to the night setting in conjunction with the position of the headlamp switch dimming control. Demonstrate to the customer the variance in the instrument panel backlighting and PRNDL display while adjusting the headlamp switch dimming control to both ends of its allowable range. Advise the customer to keep the headlight switch dimming control in the highest position to allow viewing of the PRNDL display in a bright environment. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions Ambient Light Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13211 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13212 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13213 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13214 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13215 Ambient Light Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13216 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13217 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13218 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13219 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13220 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13221 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13222 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13223 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13224 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13225 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13226 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13227 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13228 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13229 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13230 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13231 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13232 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13233 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13234 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13235 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13236 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13237 DRL Ambient Light Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 13238 Ambient Light Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the defroster grille. 2. Remove the daytime running lamp ambient light sensor socket from the defroster grille by twisting 1/4 turn counterclockwise. 3. Remove the daytime running lamp ambient light sensor from the daytime running lamp ambient light connector. INSTALLATION PROCEDURE 1. Install the daytime running lamp ambient light sensor to the daytime running lamp ambient light sensor socket. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 13239 2. Install the daytime running lamp ambient light sensor socket to the defroster grille twisting 1/4 turn clockwise. 3. Install the instrument panel upper trim pad. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations Backup Lamp Relay: Locations RH Instrument Panel Fuse Block Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations > Page 13244 Locations View In the RH instrument panel Fuse Block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Relay: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13247 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13248 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13249 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13250 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13251 Backup Lamp Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13252 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13253 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13254 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13255 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13256 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13257 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13258 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13259 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13260 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13261 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13262 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13263 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13264 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13265 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13266 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13267 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13268 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13269 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13270 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13271 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13272 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Brake Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 13277 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Locations > Component Locations Brake Lamp: Component Locations Park/Turn Signal/Stop Lamps Front and rear of the vehicle. Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Locations > Component Locations > Page 13280 Locations View Tail/Stop/Turn Lamps Rear of the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Locations > Component Locations > Page 13281 Brake Lamp: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Locations > Component Locations > Page 13282 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Stop Lamp Switch, C1 Stop Lamp Switch, C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Stop Lamp Switch, C1 > Page 13288 Stop Lamp Switch, C2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 13289 Brake Light Switch: Adjustments Notice: Proper stoplamp switch adjustment is essential. Improper stoplamp switch adjustment may cause brake drag, heat buildup and excessive brake lining wear. Important: Adjust the stoplamp switch and the cruise control switch (If equipped). at the same time. The adjustment procedure for both switches is identical. Refer to Cruise Release Switch Adjustment in order to adjust the cruise control release switch. With the brake pedal in the fully released position, ensure that the stoplamp plunger is fully depressed against the brake pedal shanks. 1. Insert the stoplamp switch and the cruise control switch (if equipped) into the brake pedal bracket. 2. Push the brake pedal forward in order to set the brake push rod into the booster. 3. Pull the brake pedal to the rear, against the internal stop. This adjusts both the stoplamp switch and the cruise control switch. 4. Inspect the stoplamp switch for proper adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 13290 Brake Light Switch: Service and Repair Removal Procedure 1. Remove the driver's side instrument panel insulator. Refer to Insulator Replacement - IP (Left) or Insulator Replacement - IP (Right) in Instrument Panel, Gauges and Warning Indicators. 2. Disconnect the electrical connectors. 3. Remove the stoplamp switch (2) from the brake pedal bracket. Installation Procedure 1. Install the stoplamp switch (2) to the brake pedal bracket. 2. Connect the electrical connectors. 3. Adjust the stoplamp switch. Refer to Stoplamp Switch Adjustment. 4. Install the driver's side instrument panel insulator. Refer to Insulator Replacement - IP (Left) or Insulator Replacement - IP (Right) in Instrument Panel, Gauges and Warning Indicators. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Specifications Center Mounted Brake Lamp: Specifications High Mounted Stop Lamp Screws 2 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Locations > Component Locations Center Mounted Brake Lamp: Component Locations Locations View Center of the rear deck lid. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Locations > Component Locations > Page 13296 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Center Mounted Brake Lamp: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13299 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13300 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13301 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13302 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13303 Center Mounted Brake Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13304 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13305 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13306 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13307 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13308 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13309 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13310 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13311 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13312 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13313 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13314 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13315 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13316 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13317 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13318 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13319 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13320 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13321 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13322 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13323 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13324 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13325 Center High Mounter Stop Lamp (CHMSL) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Page 13326 Center Mounted Brake Lamp: Service and Repair High Mounted Stoplamp Replacement REMOVAL PROCEDURE 1. Open the rear compartment. 2. Remove the screws from the high mounted stop lamp. 3. Depress the retainers holding the high mounted stop lamp to the inner panel of the compartment lid. 4. Remove the high mounted stop lamp from the rear compartment lid inner panel. 5. Disconnect the electrical connector from the high mounted stop lamp. INSTALLATION PROCEDURE 1. Connect the electrical connector to the high mounted stop lamp. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Page 13327 2. Install the high mounted stop lamp pressing in until the retainers are fully seated. 3. Install the screws to the high mounted stop lamp. Tighten Tighten the screws to the high mounted stop lamp to 2 N.m (18 lb in). 4. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions Cornering Lamp: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13332 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13333 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13334 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13335 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13336 Cornering Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13337 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13338 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13339 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13340 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13341 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13342 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13343 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13344 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13345 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13346 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13347 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13348 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13349 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13350 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13351 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13352 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13353 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13354 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13355 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13356 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13357 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Page 13358 Cornering Lamp: Service and Repair REMOVAL PROCEDURE 1. Open the hood. 2. Remove the radiator air baffle as required. 3. Remove the headlamp retainers, by pulling up. Hold the headlamp to prevent the headlamp from falling. 4. Remove the headlamp out of the slots in upper fascia support and fender reinforcement. 5. Disconnect the electrical connector from the headlamp. 6. Remove the headlamp from the vehicle. 7. Remove the rubber access cover from the headlamp for the bulb you are replacing. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Page 13359 8. Remove the bulb from the socket, turning counterclockwise. 9. Disconnect the electrical connector from the bulb. INSTALLATION PROCEDURE 1. Connect the electrical connector to the bulb. 2. Install the bulb to the socket, turning clockwise. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Page 13360 3. Install the rubber access cover to the headlamp for the bulb you are replacing. 4. Connect the electrical connector to the headlamp. 5. Install the headlamp retainers through holes in the upper fascia support and the tender reinforcement. 6. Install the headlamp retainers, by sliding downward until fully seated. 7. Check the headlamp aim, If a new headlamp was installed, or if service or repairs in the front end area were made. Refer to Headlamp Aiming (Impala) or Headlamp Aiming (Monte Carlo). 8. Install the radiator air baffle as required. 9. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Locations > Instrument Panel Ash Tray Lamp (4-Door Only) Ash Tray Lamp: Locations Instrument Panel Ash Tray Lamp (4-Door Only) In the ashtray assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Locations > Instrument Panel Ash Tray Lamp (4-Door Only) > Page 13366 Ash Tray Lamp: Locations Lamp, Ashtray (W/ Console) Center console, below the ashtray. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Locations > Instrument Panel Ash Tray Lamp (4-Door Only) > Page 13367 Ash Tray Lamp: Locations Lamp, Ashtray (W/O Console) In the ashtray assembly. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions Ash Tray Lamp: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13370 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13371 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13372 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13373 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13374 Ash Tray Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13375 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13376 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13377 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13378 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13379 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13380 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13381 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13382 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13383 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13384 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13385 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13386 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13387 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13388 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13389 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13390 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13391 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13392 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13393 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13394 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13395 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Locations Glove Box Lamp: Locations Locations View Top center of the I/P compartment opening. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Locations > Page 13399 Instrument Panel Compartment Lamp Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Locations > Page 13400 Glove Box Lamp: Service and Repair REMOVAL PROCEDURE 1. Open the instrument panel compartment door. 2. Remove the instrument panel compartment lamp switch using a small flat-bladed tool, to depress the retaining tabs. 3. Remove the compartment lamp switch from the instrument panel. 4. Disconnect the electrical connector from the instrument panel compartment lamp switch. 5. Remove the instrument panel compartment lamp switch. 6. Remove the bulb from the instrument panel lamp switch. INSTALLATION PROCEDURE 1. Install the bulb to the instrument panel compartment lamp switch. 2. Connect the electrical connector to the instrument panel compartment lamp switch. 3. Install the instrument panel compartment lamp switch into the opening in the instrument panel compartment, pressing in until fully seated. 4. Close the instrument panel compartment door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Locations > Component Locations > Page 13405 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations Daytime Running Lamp Relay: Locations Top Underhood Electrical Center Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Page 13410 Locations View Part of Underhood Accessory Wiring Junction Block (Top). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Technical Service Bulletins > IP Dimmer Control - Proper Setting Dimmer Switch: Technical Service Bulletins IP Dimmer Control - Proper Setting File In Section: 08 - Body and Accessories Bulletin No.: 99-08-42-009 Date: November, 1999 INFORMATION Subject: Proper Setting of I/P Dimmer Control to View PRNDL Display with Automatic Headlamp Control Models: 2000 and Prior All Passenger Cars and Trucks With Automatic Headlamp Control and Electronic PRNDL Display Under certain conditions, if the instrument panel dimmer control is turned relatively low, the PRNDL will not be visible until the automatic headlamp control turns the headlamps off and the daytime running lamps (DRL) are turned back on. Such a condition may be if the vehicle is first started in an environment where the headlamp control turns on the headlamps and then the vehicle is driven out into a brighter environment (for example, when a vehicle is backed out of a dark garage into the bright sunlight). This condition is normal and any repair attempt will not be successful. Demonstrate this condition to the customer using the service lane and then turn the instrument panel dimmer control to a higher setting. This will enable the driver to see the PRNDL display Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Technical Service Bulletins > Page 13415 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Locations > Component Locations Dome Lamp: Component Locations Locations View Center of the windshield header. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Locations > Component Locations > Page 13420 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions Dome Lamp: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13423 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13424 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13425 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13426 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13427 Dome Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13428 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13429 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13430 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13431 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13432 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13433 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13434 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13435 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13436 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13437 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13438 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13439 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13440 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13441 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13442 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13443 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13444 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13445 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13446 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13447 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13448 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13449 Auxiliary Dome Lamp Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Dome Lamp Replacement Dome Lamp: Service and Repair Dome Lamp Replacement REMOVAL PROCEDURE 1. Remove the dome lamp lens from the dome lamp bezel using a small flat bladed tool as a lever on the right side of the dome lamp lens. 2. Remove the dome lamp lens from the dome lamp bezel. 3. Remove the dome lamp bulb. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Dome Lamp Replacement > Page 13452 4. Remove the dome lamp bezel from the headliner using a small flat bladed tool to depress the tab retainers. 5. Remove the dome lamp from the headliner. 6. Remove the dome lamp socket from the dome lamp bezel by squeezing each terminal and pressing out. 7. Remove the dome lamp socket from the dome lamp bezel. 8. Remove the dome lamp electrical wiring from back side of the dome lamp bezel. 9. Remove the dome lamp from the vehicle. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Dome Lamp Replacement > Page 13453 1. Install the dome lamp socket to the dome lamp bezel by squeezing each terminal and pressing into place until fully seated. 2. Install the dome lamp electrical wiring to back side of the dome lamp bezel. IMPORTANT: The dome lamp bezel will not have a tight fit to the headliner until the dome lamp lens is installed. 3. Install the dome lamp bezel to the headliner pressing into place until the tab retainers are fully seated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Dome Lamp Replacement > Page 13454 4. Install the dome lamp bulb. 5. Install the dome lamp lens to the dome lamp bezel. 6. Inserting the left side of the dome lamp lens with the two retainer tabs first them pressing in the right side until fully seated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Dome Lamp Replacement > Page 13455 Dome Lamp: Service and Repair Dome Lamp Replacement, With SEO (RPO 6C7) REMOVAL PROCEDURE 1. Remove the (TRK/ROOF BRP) fuse before starting dome lamp removal procedure. 2. Remove the dome lamp lens from the dome lamp bezel using a small flat bladed tool. 3. Remove the dome lamp bulb. IMPORTANT: Hold the dome lamp bezel in position when removing the screws from the dome lamp bezel. Remove the dome lamp bezel slowly to avoid loosing the dome lamp spacers. 4. Remove the screws from the dome lamp bezel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Dome Lamp Replacement > Page 13456 5. Remove the dome lamp bezel from the headliner 6. Disconnect the electrical connector if required. INSTALLATION PROCEDURE 1. Connect the electrical connector if required. 2. Position the done lamp spaces and wiring harness ground terminal to the dome lamp bezel and screws. 3. Install the dome lamp bezel as an assembly to the dome lamp switch to the rear. Tighten Tighten the dome lamp screws to 1.5 N.m (17 lb ft). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Dome Lamp Replacement > Page 13457 4. Install the dome lamp bulb. 5. Install the dome lamp lens. 6. Install the (TRK/ROOF BRP) fuse. RPO 6C7: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Description and Operation > Park and License Lamps Exterior Lighting Module: Description and Operation Park and License Lamps The park and license lamps are controlled by the PARK LAMP relay in the RH I/P accessory wiring junction block. Both the coil and the switched sides of the relay receive B+ at all times. When the headlamp switch is turned to the PARK position, ground is supplied through the headlamp switch to the BCM through the park lamp switch input circuit. The BCM then applies a ground through the park lamp relay coil control circuit to the PARK LAMP relay. This energizes the relay, closing the switch contact and applies B+ to both the REAR PARK LAMP fuse and the FRONT PARK LAMP fuse. B+ is then applied through the park lamps ON circuit to the front and rear park lamps and the license lamps turning them on. The park lamps and license lamps receive ground at all times. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Description and Operation > Park and License Lamps > Page 13462 Exterior Lighting Module: Description and Operation Hazard Lamps The hazard lamps receive B+ at all times through the HAZARD SWITCH fuse to the hazard lamp/turn signal flasher. When the hazard switch is placed in the HAZARD position, B+ is applied to all of the turn lamps and turn indicators simultaneously flashing them on and off. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Description and Operation > Park and License Lamps > Page 13463 Exterior Lighting Module: Description and Operation Stop Lamps The stop lamps receive B+ at all times through the BRAKE SWITCH fuse to the stop lamp switch. When the stop lamp switch is closed, B+ is applied to the stop lamp switch output circuit to all the stop lamps turning them on. The stop lamps receive ground at all times. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Description and Operation > Park and License Lamps > Page 13464 Exterior Lighting Module: Description and Operation Backup Lights Circuit Description The BACKUP LAMPS Relay in the RH I/P Accessory Wiring Junction Block receives B+ at all the times for the coil side from the DIC/RKE fuse. B+ for the switched side of the relay is supplied from the B/U LAMP fuse. When the vehicle is placed in REVERSE, a class 2 signal is sent to the BCM. The BCM then applies a ground through the backup lamp relay coil feed control circuit to the backup lamps relay. This energizes the relay and allows B+ to be applied to the backup lamps turning them on. The backup lamps receive a constant ground signal Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Top Underhood Electrical Center Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 13469 Locations View Part of Underhood Accessory Wiring Junction Block (Top). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Component Locations Fog/Driving Lamp Switch: Component Locations Locations View In the LH side of instrument panel, next to the headlamp switch. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Component Locations > Page 13474 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Fog/Driving Lamp Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13477 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13478 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13479 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13480 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13481 Fog/Driving Lamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13482 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13483 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13484 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13485 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13486 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13487 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13488 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13489 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13490 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13491 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13492 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13493 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13494 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13495 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13496 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13497 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13498 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13499 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13500 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13501 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13502 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13503 Fog Lamp Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13504 Fog Lights Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Page 13505 Fog/Driving Lamp Switch: Service and Repair REMOVAL PROCEDURE 1. Remove the instrument panel cluster trim plate bezel. 2. Remove the screws from the headlamp switch housing. 3. Remove the headlamp switch housing from the instrument panel. 4. Disconnect the electrical connector from the headlamp switch. 5. Remove the headlamp switch from the headlamp switch housing. INSTALLATION PROCEDURE 1. Install the headlamp switch to the headlamp switch housing, pressing into place until fully seated. 2. Connect the electrical connector to the headlamp switch. 3. Install the headlamp switch housing to the instrument panel. 4. Install the headlamp switch housing screws. Tighten Tighten the headlamp housing switch screws to 2 Nm (18 lb in). 5. Install the instrument panel cluster trim plate bezel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Component Locations Hazard Warning Flasher: Component Locations The Hazard Flasher and Turn Signal Flasher have been integrated with the Hazard Lamp Switch. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Component Locations > Page 13511 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 13512 Hazard And Turn Signal Lamp Flasher Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Component Locations > Page 13517 Hazard Warning Switch: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Component Locations > Page 13518 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 13519 Hazard Warning Switch: Service and Repair REMOVAL PROCEDURE 1. Apply the parking brake. 2. Position the transaxle shift control indicator to 1, if equipped with column shift. 3. Adjust the steering wheel for access. 4. Remove the ignition switch cylinder bezel. 5. Remove the RH and LH instrument panel (IP) fuse block access opening covers. (Impala Only) 6. Remove the LH instrument panel (IP) fuse block access opening cover. (Monte Carlo Only) 7. Remove the steering column filler. 8. Open the instrument panel compartment door. (Monte Carlo Only) 9. Remove the IP cluster trim plate screws. 10. Start at the left side of the IP cluster trim plate. Grasp the trim plate and carefully pull rearward. Disengage the IP cluster trim plate in order to easily access the hazard warning switch. 11. Disconnect the electrical connectors from the hazard warning switch. 12. Remove the hazard warning switch from the IP cluster trim plate. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 13520 INSTALLATION PROCEDURE 1. Install the hazard warning switch to the IP cluster trim plate. 2. Connect the electrical connector to the hazard warning switch. 3. Press the IP cluster trim plate into the IP trim pad, until all of the retainers are fully seated. 4. Install the IP cluster trim plate screws. Tighten Tighten the IP cluster trim plate screws to 2 N.m (18 lb in). 5. Install the LH instrument panel (IP) fuse block access opening cover. (Monte Carlo Only) 6. Install the steering column filler. 7. Close the instrument panel compartment door. (Monte Carlo Only) 8. Install the ignition switch cylinder bezel. 9. Reposition the steering wheel to the original position. 10. Position the transaxle shift control indicator to Park, if equipped with column shift. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 13521 11. Release the parking brake. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Technical Service Bulletins > Lighting - Headlamp Polycarbonate Lens Damage Prevention Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage Prevention INFORMATION Bulletin No.: 02-08-42-001D Date: June 21, 2010 Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and to revise the warning statements. Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories). The bulletin is being issued to make dealers and customers aware of chemical damage that may be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types of headlamp lenses. This material is used because of its temperature and high impact resistance. A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when treating a vehicle with any type of chemical, such as those recommended for rail dust removal. Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash soaps in too high a concentration may also attribute to this condition. This could result in the need to replace the entire headlamp housing. Warning Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are on. This action restricts the amount of heat dissipated by the headlamps. Warning Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it could cause the lens to deform. This damage can also be caused by aftermarket shields that are often tinted in color. Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins. This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks. In more extreme cases, it will begin to melt the lens of the headlamp. Notice Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are not covered under the new vehicle warranty. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations LH Instrument Panel Fuse Block Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 13533 Locations View Inside the LH instrument panel fuse block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Component Locations Headlamp Switch: Component Locations Locations View Headlamp Switch Location LH side of the instrument panel, to the left of the steering column. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Component Locations > Page 13538 Headlamp Switch: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Component Locations > Page 13539 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13542 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13543 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13544 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13545 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13546 Headlamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13547 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13548 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13549 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13550 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13551 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13552 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13553 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13554 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13555 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13556 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13557 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13558 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13559 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13560 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13561 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13562 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13563 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13564 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13565 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13566 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13567 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13568 Headlamp Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 13569 Headlamp Switch: Service and Repair REMOVAL PROCEDURE 1. Remove the instrument panel cluster trim plate bezel. 2. Remove the screws from the headlamp switch housing. 3. Remove the headlamp switch housing from the instrument panel. 4. Disconnect the electrical connector from the headlamp switch. 5. Disconnect the electrical connector from the foglamp switch. 6. Remove the foglamp switch from the headlamp switch housing, using a small flat bladed tool. INSTALLATION PROCEDURE 1. Install the foglamp switch to the headlamp switch housing, pressing into place until fully seated. 2. Connect the electrical connector to the headlamp switch. 3. Connect the electrical connector to the foglamp switch. 4. Install the headlamp housing switch to the instrument panel. 5. Install the screws to the headlamp housing switch. Tighten Tighten the headlamp housing switch screws to 2 Nm (18 lb in). 6. Install the instrument panel cluster trim plate bezel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Top Underhood Electrical Center Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 13574 Locations View Part of Underhood Accessory Wiring Junction Block (Top). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 13575 Horn Relay: Service and Repair REMOVAL PROCEDURE 1. Open the hood. 2. Turn the underhood electrical center mounting knob counterclockwise and pull outward to remove the underhood electrical center cover. 3. Remove the horn relay (1) from the underhood electrical center. INSTALLATION PROCEDURE 1. Align the horn relay (1) to the underhood electrical center. 2. Apply pressure to the horn relay until fully seated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 13576 3. Align the underhood electrical center cover to the underhood electrical center and turn the mounting knob clockwise until fully seated. 4. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Horn Switch Location Horn Switch: Locations Horn Switch Location Behind the steering wheel inflator module. In the steering wheel inflator module. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Horn Switch Location > Page 13581 Horn Switch: Locations Horn Switch Spring Loaded Contact Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Horn Switch Location > Page 13582 Locations View Behind the steering wheel inflator module. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Locations > Component Locations > Page 13587 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Locations > Page 13588 License Plate Lamp: Service and Repair REMOVAL PROCEDURE 1. Remove the screws from the license plate lamp. 2. Remove the license plate lamp from the rear bumper fascia. 3. Remove the license plate lamp socket, turning counterclockwise. 4. Remove the bulb from the license plate lamp socket. INSTALLATION PROCEDURE 1. Install the bulb to the license plate lamp socket. 2. Install the license plate lamp socket, turning clockwise. 3. Install the license plate lamp to the rear bumper fascia. 4. Install the screws to the license plate lamp. Tighten Tighten the screws to the license plate lamp to 2 N.m (18 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Locations Map Light: Locations Mounted on the inner side of the roof rail. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13596 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13597 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13598 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13599 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13600 Marker Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13601 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13602 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13603 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13604 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13605 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13606 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13607 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13608 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13609 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13610 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13611 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13612 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13613 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13614 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13615 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13616 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13617 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13618 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13619 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13620 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13621 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 13622 Marker Lamp: Service and Repair REMOVAL PROCEDURE 1. Open the hood. 2. Remove the radiator air baffle as required. 3. Remove the headlamp retainers, by pulling up. Hold the headlamp to prevent the headlamp from falling. 4. Remove the headlamp out of the slots in upper fascia support and fender reinforcement. 5. Disconnect the electrical connector from the headlamp. 6. Remove the headlamp from the vehicle. 7. Remove the rubber access cover from the headlamp for the bulb you are replacing. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 13623 8. Remove the bulb from the socket, turning counterclockwise. 9. Disconnect the electrical connector from the bulb. INSTALLATION PROCEDURE 1. Connect the electrical connector to the bulb. 2. Install the bulb to the socket, turning clockwise. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 13624 3. Install the rubber access cover to the headlamp for the bulb you are replacing. 4. Connect the electrical connector to the headlamp. 5. Install the headlamp retainers through holes in the upper fascia support and the tender reinforcement. 6. Install the headlamp retainers, by sliding downward until fully seated. 7. Check the headlamp aim, If a new headlamp was installed, or if service or repairs in the front end area were made. Refer to Headlamp Aiming (Impala) or Headlamp Aiming (Monte Carlo). 8. Install the radiator air baffle as required. 9. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations RH Instrument Panel Fuse Block Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 13629 Locations View In the RH instrument panel Fuse Block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations Backup Lamp Relay: Locations RH Instrument Panel Fuse Block Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 13634 Locations View In the RH instrument panel Fuse Block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Relay: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13637 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13638 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13639 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13640 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13641 Backup Lamp Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13642 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13643 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13644 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13645 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13646 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13647 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13648 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13649 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13650 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13651 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13652 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13653 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13654 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13655 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13656 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13657 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13658 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13659 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13660 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13661 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13662 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations Daytime Running Lamp Relay: Locations Top Underhood Electrical Center Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 13666 Locations View Part of Underhood Accessory Wiring Junction Block (Top). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Description and Operation > Park and License Lamps Exterior Lighting Module: Description and Operation Park and License Lamps The park and license lamps are controlled by the PARK LAMP relay in the RH I/P accessory wiring junction block. Both the coil and the switched sides of the relay receive B+ at all times. When the headlamp switch is turned to the PARK position, ground is supplied through the headlamp switch to the BCM through the park lamp switch input circuit. The BCM then applies a ground through the park lamp relay coil control circuit to the PARK LAMP relay. This energizes the relay, closing the switch contact and applies B+ to both the REAR PARK LAMP fuse and the FRONT PARK LAMP fuse. B+ is then applied through the park lamps ON circuit to the front and rear park lamps and the license lamps turning them on. The park lamps and license lamps receive ground at all times. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Description and Operation > Park and License Lamps > Page 13671 Exterior Lighting Module: Description and Operation Hazard Lamps The hazard lamps receive B+ at all times through the HAZARD SWITCH fuse to the hazard lamp/turn signal flasher. When the hazard switch is placed in the HAZARD position, B+ is applied to all of the turn lamps and turn indicators simultaneously flashing them on and off. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Description and Operation > Park and License Lamps > Page 13672 Exterior Lighting Module: Description and Operation Stop Lamps The stop lamps receive B+ at all times through the BRAKE SWITCH fuse to the stop lamp switch. When the stop lamp switch is closed, B+ is applied to the stop lamp switch output circuit to all the stop lamps turning them on. The stop lamps receive ground at all times. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Description and Operation > Park and License Lamps > Page 13673 Exterior Lighting Module: Description and Operation Backup Lights Circuit Description The BACKUP LAMPS Relay in the RH I/P Accessory Wiring Junction Block receives B+ at all the times for the coil side from the DIC/RKE fuse. B+ for the switched side of the relay is supplied from the B/U LAMP fuse. When the vehicle is placed in REVERSE, a class 2 signal is sent to the BCM. The BCM then applies a ground through the backup lamp relay coil feed control circuit to the backup lamps relay. This energizes the relay and allows B+ to be applied to the backup lamps turning them on. The backup lamps receive a constant ground signal Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Top Underhood Electrical Center Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 13677 Locations View Part of Underhood Accessory Wiring Junction Block (Top). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations LH Instrument Panel Fuse Block Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 13681 Locations View Inside the LH instrument panel fuse block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Top Underhood Electrical Center Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 13685 Locations View Part of Underhood Accessory Wiring Junction Block (Top). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 13686 Horn Relay: Service and Repair REMOVAL PROCEDURE 1. Open the hood. 2. Turn the underhood electrical center mounting knob counterclockwise and pull outward to remove the underhood electrical center cover. 3. Remove the horn relay (1) from the underhood electrical center. INSTALLATION PROCEDURE 1. Align the horn relay (1) to the underhood electrical center. 2. Apply pressure to the horn relay until fully seated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 13687 3. Align the underhood electrical center cover to the underhood electrical center and turn the mounting knob clockwise until fully seated. 4. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations RH Instrument Panel Fuse Block Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 13691 Locations View In the RH instrument panel Fuse Block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions Ambient Light Sensor: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13697 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13698 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13699 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13700 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13701 Ambient Light Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13702 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13703 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13704 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13705 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13706 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13707 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13708 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13709 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13710 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13711 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13712 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13713 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13714 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13715 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13716 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13717 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13718 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13719 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13720 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13721 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13722 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 13723 DRL Ambient Light Sensor Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 13724 Ambient Light Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the defroster grille. 2. Remove the daytime running lamp ambient light sensor socket from the defroster grille by twisting 1/4 turn counterclockwise. 3. Remove the daytime running lamp ambient light sensor from the daytime running lamp ambient light connector. INSTALLATION PROCEDURE 1. Install the daytime running lamp ambient light sensor to the daytime running lamp ambient light sensor socket. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 13725 2. Install the daytime running lamp ambient light sensor socket to the defroster grille twisting 1/4 turn clockwise. 3. Install the instrument panel upper trim pad. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Stop Lamp Switch, C1 Stop Lamp Switch, C1 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Stop Lamp Switch, C1 > Page 13731 Stop Lamp Switch, C2 Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 13732 Brake Light Switch: Adjustments Notice: Proper stoplamp switch adjustment is essential. Improper stoplamp switch adjustment may cause brake drag, heat buildup and excessive brake lining wear. Important: Adjust the stoplamp switch and the cruise control switch (If equipped). at the same time. The adjustment procedure for both switches is identical. Refer to Cruise Release Switch Adjustment in order to adjust the cruise control release switch. With the brake pedal in the fully released position, ensure that the stoplamp plunger is fully depressed against the brake pedal shanks. 1. Insert the stoplamp switch and the cruise control switch (if equipped) into the brake pedal bracket. 2. Push the brake pedal forward in order to set the brake push rod into the booster. 3. Pull the brake pedal to the rear, against the internal stop. This adjusts both the stoplamp switch and the cruise control switch. 4. Inspect the stoplamp switch for proper adjustment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 13733 Brake Light Switch: Service and Repair Removal Procedure 1. Remove the driver's side instrument panel insulator. Refer to Insulator Replacement - IP (Left) or Insulator Replacement - IP (Right) in Instrument Panel, Gauges and Warning Indicators. 2. Disconnect the electrical connectors. 3. Remove the stoplamp switch (2) from the brake pedal bracket. Installation Procedure 1. Install the stoplamp switch (2) to the brake pedal bracket. 2. Connect the electrical connectors. 3. Adjust the stoplamp switch. Refer to Stoplamp Switch Adjustment. 4. Install the driver's side instrument panel insulator. Refer to Insulator Replacement - IP (Left) or Insulator Replacement - IP (Right) in Instrument Panel, Gauges and Warning Indicators. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Component Locations Fog/Driving Lamp Switch: Component Locations Locations View In the LH side of instrument panel, next to the headlamp switch. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Component Locations > Page 13738 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Fog/Driving Lamp Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13741 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13742 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13743 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13744 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13745 Fog/Driving Lamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13746 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13747 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13748 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13749 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13750 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13751 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13752 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13753 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13754 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13755 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13756 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13757 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13758 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13759 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13760 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13761 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13762 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13763 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13764 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13765 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13766 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13767 Fog Lamp Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13768 Fog Lights Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Page 13769 Fog/Driving Lamp Switch: Service and Repair REMOVAL PROCEDURE 1. Remove the instrument panel cluster trim plate bezel. 2. Remove the screws from the headlamp switch housing. 3. Remove the headlamp switch housing from the instrument panel. 4. Disconnect the electrical connector from the headlamp switch. 5. Remove the headlamp switch from the headlamp switch housing. INSTALLATION PROCEDURE 1. Install the headlamp switch to the headlamp switch housing, pressing into place until fully seated. 2. Connect the electrical connector to the headlamp switch. 3. Install the headlamp switch housing to the instrument panel. 4. Install the headlamp switch housing screws. Tighten Tighten the headlamp housing switch screws to 2 Nm (18 lb in). 5. Install the instrument panel cluster trim plate bezel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Locations > Component Locations > Page 13774 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Component Locations > Page 13779 Hazard Warning Switch: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Component Locations > Page 13780 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 13781 Hazard Warning Switch: Service and Repair REMOVAL PROCEDURE 1. Apply the parking brake. 2. Position the transaxle shift control indicator to 1, if equipped with column shift. 3. Adjust the steering wheel for access. 4. Remove the ignition switch cylinder bezel. 5. Remove the RH and LH instrument panel (IP) fuse block access opening covers. (Impala Only) 6. Remove the LH instrument panel (IP) fuse block access opening cover. (Monte Carlo Only) 7. Remove the steering column filler. 8. Open the instrument panel compartment door. (Monte Carlo Only) 9. Remove the IP cluster trim plate screws. 10. Start at the left side of the IP cluster trim plate. Grasp the trim plate and carefully pull rearward. Disengage the IP cluster trim plate in order to easily access the hazard warning switch. 11. Disconnect the electrical connectors from the hazard warning switch. 12. Remove the hazard warning switch from the IP cluster trim plate. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 13782 INSTALLATION PROCEDURE 1. Install the hazard warning switch to the IP cluster trim plate. 2. Connect the electrical connector to the hazard warning switch. 3. Press the IP cluster trim plate into the IP trim pad, until all of the retainers are fully seated. 4. Install the IP cluster trim plate screws. Tighten Tighten the IP cluster trim plate screws to 2 N.m (18 lb in). 5. Install the LH instrument panel (IP) fuse block access opening cover. (Monte Carlo Only) 6. Install the steering column filler. 7. Close the instrument panel compartment door. (Monte Carlo Only) 8. Install the ignition switch cylinder bezel. 9. Reposition the steering wheel to the original position. 10. Position the transaxle shift control indicator to Park, if equipped with column shift. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 13783 11. Release the parking brake. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Component Locations Headlamp Switch: Component Locations Locations View Headlamp Switch Location LH side of the instrument panel, to the left of the steering column. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Component Locations > Page 13791 Headlamp Switch: Connector Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Component Locations > Page 13792 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13795 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13796 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13797 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13798 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13799 Headlamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13800 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13801 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13802 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13803 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13804 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13805 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13806 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13807 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13808 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13809 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13810 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13811 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13812 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13813 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13814 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13815 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13816 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13817 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13818 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13819 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13820 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13821 Headlamp Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 13822 Headlamp Switch: Service and Repair REMOVAL PROCEDURE 1. Remove the instrument panel cluster trim plate bezel. 2. Remove the screws from the headlamp switch housing. 3. Remove the headlamp switch housing from the instrument panel. 4. Disconnect the electrical connector from the headlamp switch. 5. Disconnect the electrical connector from the foglamp switch. 6. Remove the foglamp switch from the headlamp switch housing, using a small flat bladed tool. INSTALLATION PROCEDURE 1. Install the foglamp switch to the headlamp switch housing, pressing into place until fully seated. 2. Connect the electrical connector to the headlamp switch. 3. Connect the electrical connector to the foglamp switch. 4. Install the headlamp housing switch to the instrument panel. 5. Install the screws to the headlamp housing switch. Tighten Tighten the headlamp housing switch screws to 2 Nm (18 lb in). 6. Install the instrument panel cluster trim plate bezel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Horn Switch Location Horn Switch: Locations Horn Switch Location Behind the steering wheel inflator module. In the steering wheel inflator module. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Horn Switch Location > Page 13827 Horn Switch: Locations Horn Switch Spring Loaded Contact Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Horn Switch Location > Page 13828 Locations View Behind the steering wheel inflator module. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Hazard Lamp/Turn Signal Lamp Flasher Switch Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Hazard Lamp/Turn Signal Lamp Flasher Switch > Page 13833 Turn Signal Switch: Locations Multifunction Lever Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Hazard Lamp/Turn Signal Lamp Flasher Switch > Page 13834 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Hazard Lamp/Turn Signal Lamp Flasher Switch > Page 13835 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Hazard Lamp/Turn Signal Lamp Flasher Switch > Page 13836 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Hazard Lamp/Turn Signal Lamp Flasher Switch > Page 13837 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13840 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13841 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13842 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13843 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13844 Turn Signal Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13845 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13846 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13847 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13848 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13849 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13850 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13851 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13852 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13853 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13854 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13855 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13856 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13857 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13858 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13859 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13860 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13861 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13862 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13863 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13864 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13865 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 13866 Turn Signal Switch: Service and Repair Removal Procedure 1. Verify that the multifunction turn signal lever is in the center of the OFF position. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging 3. Disable the SIR system. Refer to Disabling the SIR System in Air Bags and Seat Belts. 4. Remove the steering wheel. Refer to Steering Wheel Replacement. 5. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement - On Vehicle. 6. Remove the steering column wire harness (1) from the steering column wire harness retainer (2). 7. Remove the two wire harness straps from the steering column wire harness (1). 8. Remove the steering column bulkhead connector from the vehicle wire harness. 9. Disconnect the connectors from the multifunction turn signal lever steering column bulkhead connector. 10. Remove the retaining bolts (1) from the multifunction turn signal lever (2). 11. Remove the multifunction turn signal lever (2) from the steering column. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 13867 1. Install the multifunction turn signal lever (2). Use a small flat-blade in order to compress the electrical contact and move the multifunction turn signal lever into position. 2. Verify that the electrical contact rests on the canceling cam. Notice: Refer to Fastener Notice in Service Precautions 3. Install the retaining bolts to the multifunction turn signal lever. Tighten the retaining bolts to 7 Nm (62 inch lbs.). 4. Connect the gray and black connectors to the multifunction turn signal lever steering column bulkhead connector. 5. Connect the steering column bulkhead connector to the vehicle wire harness. 6. Install the two wire harness straps to the steering column wire harness (1). 7. Install the steering column wire harness (1) to the steering column wire harness retainer (2). 8. Install the steering column trim cover. Refer to Steering Column Trim Cover Replacement - On Vehicle. 9. Verify that the lever is in the center or the OFF position. 10. Install the steering wheel to the steering column. Refer to Steering Wheel Replacement 11. Enable the SIR system. Refer to Enabling the SIR System in Air Bags and Seat Belts 12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Locations > Component Locations Spot Lamp: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Locations > Component Locations > Page 13872 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Locations > Component Locations > Page 13873 Spot Lamp: Connector Locations Spot Lamp Connector, RH Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Locations > Component Locations > Page 13874 Locations View RPO 9C1/9C6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Spot Lamp Connector, LH Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Locations > Component Locations > Page 13875 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Locations > Component Locations > Page 13876 Locations View RPO 9C1/9C6: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Locations > Component Locations > Page 13877 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions Spot Lamp: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13880 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13881 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13882 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13883 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13884 Spot Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13885 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13886 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13887 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13888 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13889 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13890 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13891 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13892 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13893 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13894 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13895 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13896 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13897 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13898 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13899 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13900 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13901 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13902 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13903 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13904 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13905 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Service and Repair > Spotlamp Replacement (SEO) Spot Lamp: Service and Repair Spotlamp Replacement (SEO) REMOVAL PROCEDURE 1. Remove the spotlamp wiring harness push-in retainer from the windshield garnish molding, using a small flat bladed tool. 2. Disconnect the electrical connector. 3. Remove the spotlamp handle wedge key screw from the spotlamp handle. Loosen the wedge key screw a few turns then with a light tap with a suitable hammer to the wedge key screw will loosen it from the spotlamp outer tube shaft. 4. Remove the spotlamp handle from the outer tube shaft. 5. Remove the rubber grommet from the outer tube shaft. 6. Loosen the spotlamp bracket set screw. 7. Pull the spotlamp with the outer tube shaft out of the spotlamp mounting bracket and set aside. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Service and Repair > Spotlamp Replacement (SEO) > Page 13908 8. Remove the spotlamp mounting bracket screws. 9. Remove the mounting bracket and the gasket from the windshield pillar. 10. Clean the mounting surface of the windshield pillar. INSTALLATION PROCEDURE IMPORTANT: This method of installation will stop the chance of any alignment and binding problems. 1. Install the mounting bracket and the gasket on to the spotlamp outer tube shaft. 2. Apply a small amount of RTV sealer GM P/N 12345336 or equivalent to the screw holes on the windshield pillar. 3. Install the mounting bracket, the gasket and the spotlamp outer tube shaft through the windshield pillar. 4. Install the spotlamp mounting bracket screws. Tighten Tighten the mounting bracket screws to 3.5 N.m (31 lb in). 5. Rotate the spotlamp to the upright position. Point the spotlamp forward. 6. Tighten the spotlamp mounting bracket set screw just enough in order to firmly hold the spotlamp in the upright position. 7. Install the rubber grommet to the outer tube shaft. 8. Install the spotlamp handle onto the outer tube shaft in the vertical down position until the handle bottoms out, and the flat detent on the outer tube shaft is exposed through the wedge key screw hole. 9. Install the spotlamp wedge key screw. Tighten Tighten the spotlamp wedge key screw to 7.5 N.m (66 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Service and Repair > Spotlamp Replacement (SEO) > Page 13909 10. Connect the electrical connector. 11. Install the spotlamp wiring harness push-in retainer to the windshield garnish molding, pressing in until fully seated. 12. Inspect the spotlamp for proper operation. ^ The handle must rotate the spotlamp approximately 90 degrees about the spotlamp shaft axis from the parked position to the vertical position. ^ The spotlamp head must rotate 360 degrees about its axis. ^ The spotlamp must able to be turned ON/OFF independent of the ignition switch. 13. If spotlamp adjustment and/or electrical diagnosis are required, refer to the following procedures. ^ For spotlamp travel adjustment, refer to Spotlamp Travel Adjustment (SEO) (Impala RPO 7X6, 7X7). ^ For electrical diagnosis, refer to Power Distribution Schematics in Diagrams. RPO CODE: For a Description of RPO Code(s) shown in this article refer to the RPO Code List found at Vehicle/Application and ID See: Application and ID/RPO Codes Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Service and Repair > Spotlamp Replacement (SEO) > Page 13910 Spot Lamp: Service and Repair Spotlamp Bulb Replacement (SEO) REMOVAL PROCEDURE 1. Remove the spotlamp wiring harness push-in retainer from the windshield garnish molding, using a small flat bladed tool. 2. Disconnect the electrical connector. IMPORTANT: Hold the spotlamp seal beam in position. 3. Remove the screws from the spotlamp bezel. 4. Remove the spotlamp bezel from the spotlamp. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Service and Repair > Spotlamp Replacement (SEO) > Page 13911 5. Remove the sealbeam from the spotlamp. 6. Loosen the screws to the electrical connectors on the back of the spotlamp sealbeam. 7. Remove the electrical connectors from the back of the spotlamp sealbeam. 8. Remove the sealbeam from the spotlamp. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Service and Repair > Spotlamp Replacement (SEO) > Page 13912 1. Connect the electrical connectors to the back of the sealbeam. 2. Tighten the screws to the electrical connectors. Tighten Tighten the screws to the electrical connectors to 2 N.m (18 lb in). IMPORTANT: The sealbeam must be clocked in the UP position, refer to the emblem on the face of the sealbeam. 3. Install the sealbeam to the spotlamp. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Service and Repair > Spotlamp Replacement (SEO) > Page 13913 4. Hold the spotlamp seal beam in position. 5. Install the spotlamp bezel to the spotlamp. 6. Install the screws from the spotlamp bezel. Tighten Tighten the screws to the spotlamp bezel to 2 N.m (18 lb in). 7. Install the spotlamp wiring harness push-in retainer from the windshield garnish molding, using a small flat bladed tool. 8. Connect the electrical connector. 9. Inspect the spotlamp for proper operation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Service and Repair > Spotlamp Replacement (SEO) > Page 13914 Spot Lamp: Service and Repair Spotlamp Travel Adjustment (SEO) 1. Loosen the spotlamp bracket clamp bolt. 2. Grasp the spotlamp. Slowly rotate the spotlamp inboard until the shaft contacts the parkstop position. 3. Rotate the spotlamp slowly outboard to 5 degrees past the vertical position in order for the backstop to be in motion and the outer tube shaft to rotate. 4. Tighten the bracket clamp bolt sufficiently, in order to prevent the outer shaft tube from rotating while the spotlamp is moving between the stop positions. 5. Rotate the spotlamp head inboard to the parkstop position in order to prevent the spotlamp from coming in contact with the body components. 6. Position the parkstop of the shaft in order to rotate the spotlamp on its axis, clearing the nearest body components by 13-0.5 mm (0.50-0.02 in). 7. Tighten the bracket clamp screw when the parkstop has been set, in order to prevent rotation of the spotlamp shaft. Tighten Tighten the spotlight bracket clamp bolt to 6 N.m (53 lb in). 8. Adjust the spotlamp head clamping bolt, in order to easily rotate the spotlamp (1200) in any adjustable position between the parkstop and the backstop positions. The total motion of the spotlamp is approximately 90 degrees. Tighten Tighten the spotlight head clamping bolt to 2.5 N.m (22 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Tail Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 13919 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Locations > Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Locations > Component Locations > Page 13922 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13925 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13926 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13927 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13928 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13929 Tail Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13930 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13931 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13932 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13933 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13934 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13935 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13936 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13937 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13938 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13939 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13940 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13941 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13942 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13943 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13944 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13945 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13946 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13947 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13948 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13949 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13950 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 13951 Tail Lamp: Service and Repair REMOVAL PROCEDURE 1. Open the rear compartment. 2. Disconnect the rear compartment convenience net. 3. Remove wingnut and pull back the rear compartment trim panel from the taillamp. 4. Remove the wingnuts from the taillamp. 5. Remove the taillamp from the rear body panel. 6. Disconnect the electrical connector from the taillamp. 7. Remove the taillamp socket, turning counterclockwise. 8. Remove the bulb from the taillamp socket. 9. Remove the sidemarker lamp socket, turning counterclockwise. 10. Remove the bulb from the sidemarker lamp socket. INSTALLATION PROCEDURE 1. Install the bulb to the taillamp socket. 2. Install the bulb to the sidemarker lamp socket. 3. Install the sidemarker lamp socket, turning clockwise. 4. Install the taillamp socket, turning clockwise. 5. Connect the electrical connector to the taillamp. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 13952 6. Install the taillamp to the rear body panel 7. Install the wingnuts.to the taillamp. 8. Pull back the rear compartment trim panel to the taillamp and install the wingnut. 9. Connect the rear compartment convenience net. 10. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Service and Repair Trunk Lamp: Service and Repair REMOVAL PROCEDURE 1. Open the rear compartment. 2. Remove the rear compartment lamp using a small flat-bladed tool to release the retaining tabs. 3. Remove the bulb from the rear compartment lamp socket. INSTALLATION PROCEDURE 1. Install the bulb to the rear compartment lamp socket. 2. Install the rear compartment lamp, pressing into place until full seated. 3. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Component Locations Turn Signal Flasher: Component Locations Locations View The turn signal and hazard lamp flasher is part of the hazard switch. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Component Locations > Page 13961 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Flasher: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13964 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13965 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13966 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13967 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13968 Turn Signal Flasher: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13969 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13970 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13971 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13972 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13973 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13974 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13975 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13976 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13977 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13978 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13979 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13980 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13981 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13982 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13983 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13984 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13985 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13986 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13987 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13988 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13989 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 13990 Hazard And Turn Signal Lamp Flasher Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Turn Signal Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 13995 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Locations > Hazard and Turn Signal Lamp Flasher Turn Signal Lamp: Locations Hazard and Turn Signal Lamp Flasher Behind the LH side of the I/P, mounted in the bulkhead. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Locations > Hazard and Turn Signal Lamp Flasher > Page 13998 Turn Signal Lamp: Locations Hazard Lamp/Turn Signal Lamp Flasher Integral with hazard switch. Behind the LH side of the instrument panel, mounted in the bulkhead; part of the hazard switch. Incorporated in with the hazard switch. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Locations > Hazard and Turn Signal Lamp Flasher > Page 13999 Turn Signal Lamp: Locations Park/Turn Signal/Stop Lamps Front and rear of the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Locations > Hazard and Turn Signal Lamp Flasher > Page 14000 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Locations > Hazard and Turn Signal Lamp Flasher > Page 14001 Turn Signal Lamp: Locations Hazard and Turn Signal Lamp Flasher Behind the LH side of the I/P, mounted in the bulkhead. Hazard Lamp/Turn Signal Lamp Flasher Integral with hazard switch. Behind the LH side of the instrument panel, mounted in the bulkhead; part of the hazard switch. Incorporated in with the hazard switch. Park/Turn Signal/Stop Lamps Front and rear of the vehicle. Locations View Tail/Stop/Turn Lamps Rear of the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Locations > Hazard and Turn Signal Lamp Flasher > Page 14002 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Lamp: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14005 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14006 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14007 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14008 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14009 Turn Signal Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14010 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14011 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14012 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14013 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14014 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14015 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14016 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14017 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14018 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14019 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14020 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14021 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14022 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14023 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14024 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14025 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14026 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14027 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14028 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14029 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14030 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Page 14031 Turn Signal Lamp: Service and Repair REMOVAL PROCEDURE 1. Open the hood. 2. Remove the radiator air baffle as required. 3. Remove the headlamp retainers, by pulling up. Hold the headlamp to prevent the headlamp from falling. 4. Remove the headlamp out of the slots in upper fascia support and fender reinforcement. 5. Disconnect the electrical connector from the headlamp. 6. Remove the headlamp from the vehicle. 7. Remove the rubber access cover from the headlamp for the bulb you are replacing. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Page 14032 8. Remove the bulb from the socket, turning counterclockwise. 9. Disconnect the electrical connector from the bulb. INSTALLATION PROCEDURE 1. Connect the electrical connector to the bulb. 2. Install the bulb to the socket, turning clockwise. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Page 14033 3. Install the rubber access cover to the headlamp for the bulb you are replacing. 4. Connect the electrical connector to the headlamp. 5. Install the headlamp retainers through holes in the upper fascia support and the tender reinforcement. 6. Install the headlamp retainers, by sliding downward until fully seated. 7. Check the headlamp aim, If a new headlamp was installed, or if service or repairs in the front end area were made. Refer to Headlamp Aiming (Impala) or Headlamp Aiming (Monte Carlo). 8. Install the radiator air baffle as required. 9. Close the hood. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Hazard Lamp/Turn Signal Lamp Flasher Switch Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Hazard Lamp/Turn Signal Lamp Flasher Switch > Page 14038 Turn Signal Switch: Locations Multifunction Lever Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Hazard Lamp/Turn Signal Lamp Flasher Switch > Page 14039 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Hazard Lamp/Turn Signal Lamp Flasher Switch > Page 14040 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Hazard Lamp/Turn Signal Lamp Flasher Switch > Page 14041 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Hazard Lamp/Turn Signal Lamp Flasher Switch > Page 14042 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14045 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14046 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14047 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14048 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14049 Turn Signal Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14050 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14051 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14052 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14053 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14054 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14055 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14056 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14057 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14058 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14059 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14060 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14061 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14062 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14063 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14064 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14065 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14066 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14067 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14068 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14069 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14070 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 14071 Turn Signal Switch: Service and Repair Removal Procedure 1. Verify that the multifunction turn signal lever is in the center of the OFF position. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging 3. Disable the SIR system. Refer to Disabling the SIR System in Air Bags and Seat Belts. 4. Remove the steering wheel. Refer to Steering Wheel Replacement. 5. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement - On Vehicle. 6. Remove the steering column wire harness (1) from the steering column wire harness retainer (2). 7. Remove the two wire harness straps from the steering column wire harness (1). 8. Remove the steering column bulkhead connector from the vehicle wire harness. 9. Disconnect the connectors from the multifunction turn signal lever steering column bulkhead connector. 10. Remove the retaining bolts (1) from the multifunction turn signal lever (2). 11. Remove the multifunction turn signal lever (2) from the steering column. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 14072 1. Install the multifunction turn signal lever (2). Use a small flat-blade in order to compress the electrical contact and move the multifunction turn signal lever into position. 2. Verify that the electrical contact rests on the canceling cam. Notice: Refer to Fastener Notice in Service Precautions 3. Install the retaining bolts to the multifunction turn signal lever. Tighten the retaining bolts to 7 Nm (62 inch lbs.). 4. Connect the gray and black connectors to the multifunction turn signal lever steering column bulkhead connector. 5. Connect the steering column bulkhead connector to the vehicle wire harness. 6. Install the two wire harness straps to the steering column wire harness (1). 7. Install the steering column wire harness (1) to the steering column wire harness retainer (2). 8. Install the steering column trim cover. Refer to Steering Column Trim Cover Replacement - On Vehicle. 9. Verify that the lever is in the center or the OFF position. 10. Install the steering wheel to the steering column. Refer to Steering Wheel Replacement 11. Enable the SIR system. Refer to Enabling the SIR System in Air Bags and Seat Belts 12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Service and Repair Underhood Lamp: Service and Repair Underhood Lamp Replacement REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the underhood lamp. 3. Remove the harness retainers from the hood using a small flat-bladed tool. 4. Remove the harness retainers from the shock tower using a small flat-bladed tool. 5. Apply pressure to the retainer behind the connector on the underhood lamp using a small flat-bladed tool. 6. Remove the underhood lamp from the hood. INSTALLATION PROCEDURE 1. Install the underhood lamp to the hood. 2. Align the tab at the top of the underhood lamp to the slot in the hood. Push in the tab. 3. Align the lower snap tab at the bottom of the underhood lamp to the slot in the hood. Press down the tab. 4. Install the harness retainers to the hood. 5. Install the harness retainers to the shock tower. 6. Connect the electrical connector to the underhood lamp. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 7. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Service and Repair Vanity Lamp: Service and Repair REMOVAL PROCEDURE 1. Lower the sunshade and raise the mirror and the lamp cover (the door). 2. Insert a small flat-bladed screwdriver at the lower edge of the vanity mirror lamp lens then gently pry down to release the lens. 3. Remove the vanity mirror lamp lens from the sunshade. 4. Remove the bulb from the socket. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Service and Repair > Page 14079 1. Install the bulb into the socket. 2. Position the vanity mirror lamp lens to the sunshade. Align the lens tabs into the housing slots and insert the upper edge of the lens first. 3. Insert a small flat-bladed screwdriver at the lower edge of the vanity mirror lamp lens then gently pry up to fully install the lens. 4. Close the lamp cover door and raise the sunshade. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations In the RH instrument panel accessory wiring junction block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Rear Defogger Relay > Component Information > Locations Rear Defogger Relay: Locations RH Instrument Panel Fuse Block Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Rear Defogger Relay > Component Information > Locations > Page 14089 Locations View In the RH instrument panel Fuse Block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations In the RH instrument panel accessory wiring junction block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations Rear Defogger Relay: Locations RH Instrument Panel Fuse Block Label Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations > Page 14097 Locations View In the RH instrument panel Fuse Block. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Locations > Component Locations Power Window Lockout Switch: Component Locations In the LF door, part of the master window switch. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Locations > Component Locations > Page 14103 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations Power Window Switch: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 14108 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 14109 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 14110 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 14111 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 14112 Power Window Switch: Connector Locations Locations View Window Switch Connector Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 14113 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 14114 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 14115 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 14116 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14119 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14120 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14121 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14122 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14123 Power Window Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14124 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14125 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14126 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14127 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14128 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14129 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14130 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14131 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14132 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14133 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14134 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14135 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14136 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14137 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14138 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14139 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14140 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14141 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14142 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14143 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14144 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14145 Power Window Switch: Connector Views Window Switch, LF, C1 (4 Door) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14146 Window Switch, LF, C2 (2 Door) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14147 Window Switch, LF, C2 (4 Door) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement Power Window Switch: Service and Repair Front Side Door Window Switch Replacement Front Side Door Window Switch Replacement (Impala) Removal Procedure 1. Remove the front door pull cup screws (1) and pull cup from the front door trim panel. Armrest Pull Cup Replacement (Impala) (See: Body and Frame/Interior Moulding / Trim/Arm Rest/Service and Repair/Removal and Replacement/Armrest Pull Cup Replacement). 2. Disconnect the electrical connectors from the front door power window control switch. 3. Remove the front door window control switch using a small, flat-bladed tool at the side of the switch. Installation Procedure 1. Install the front door power window control switch to the front door pull cup pressing into place until fully seated. 2. Connect the electrical connector to the power window control switch. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement > Page 14150 3. Install the front door pull cup and screws (1) to the front door trim panel. Armrest Pull Cup Replacement (Impala) (See: Body and Frame/Interior Moulding / Trim/Arm Rest/Service and Repair/Removal and Replacement/Armrest Pull Cup Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement > Page 14151 Power Window Switch: Service and Repair Power Window Switch Replacement REMOVAL PROCEDURE 1. Remove the front door pull cup from the front door trim panel. Armrest Pull Cup Replacement (Impala). 2. Disconnect the electrical connectors from the front door power window control switch. 3. Remove the front door window control switch from the front door pull cup using a small flat-bladed tool at the side of the power window control switch in order to release the front door power window control switch retainer. INSTALLATION PROCEDURE 1. Install the front door power window control switch to the front door pull cup pressing into place until fully seated. 2. Connect the electrical connectors to the front door power window control switch. 3. Install the front door pull cup to the front door trim panel. Armrest Pull Cup Replacement (Impala). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement > Page 14152 Power Window Switch: Service and Repair Rear Door Power Window Switch Replacement REMOVAL PROCEDURE 1. Remove the rear door pull cup from the rear door trim panel. 2. Disconnect the electrical connectors from the power window control switch. 3. Remove the rear door window control switch from the front door pull cup using a small flat-bladed tool at the side of the power window control switch in order to release the power window control switch retainer. 4. Remove the power window control switch from the rear door pull cup. INSTALLATION PROCEDURE 1. Install the rear door power window control switch to the rear door pull cup pressing into place until fully seated. 2. Connect the electrical connectors to the rear door power window control switch. 3. Install the rear door pull cup to the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Lockout Switch > Component Information > Locations > Component Locations Power Window Lockout Switch: Component Locations In the LF door, part of the master window switch. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Lockout Switch > Component Information > Locations > Component Locations > Page 14158 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair Front Side Door Window Regulator Motor Replacement Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair Rear Door Window Motor: Service and Repair Rear Side Door Window Regulator Motor Replacement Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Component Locations Power Window Switch: Component Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Component Locations > Page 14170 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Component Locations > Page 14171 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Component Locations > Page 14172 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Component Locations > Page 14173 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Component Locations > Page 14174 Power Window Switch: Connector Locations Locations View Window Switch Connector Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Component Locations > Page 14175 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Component Locations > Page 14176 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Component Locations > Page 14177 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Component Locations > Page 14178 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14181 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14182 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14183 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14184 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14185 Power Window Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14186 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14187 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14188 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14189 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14190 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14191 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14192 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14193 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14194 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14195 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14196 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14197 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14198 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14199 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14200 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14201 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14202 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14203 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14204 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14205 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14206 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14207 Power Window Switch: Connector Views Window Switch, LF, C1 (4 Door) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14208 Window Switch, LF, C2 (2 Door) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14209 Window Switch, LF, C2 (4 Door) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement Power Window Switch: Service and Repair Front Side Door Window Switch Replacement Front Side Door Window Switch Replacement (Impala) Removal Procedure 1. Remove the front door pull cup screws (1) and pull cup from the front door trim panel. Armrest Pull Cup Replacement (Impala) (See: Body and Frame/Interior Moulding / Trim/Arm Rest/Service and Repair/Removal and Replacement/Armrest Pull Cup Replacement). 2. Disconnect the electrical connectors from the front door power window control switch. 3. Remove the front door window control switch using a small, flat-bladed tool at the side of the switch. Installation Procedure 1. Install the front door power window control switch to the front door pull cup pressing into place until fully seated. 2. Connect the electrical connector to the power window control switch. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement > Page 14212 3. Install the front door pull cup and screws (1) to the front door trim panel. Armrest Pull Cup Replacement (Impala) (See: Body and Frame/Interior Moulding / Trim/Arm Rest/Service and Repair/Removal and Replacement/Armrest Pull Cup Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement > Page 14213 Power Window Switch: Service and Repair Power Window Switch Replacement REMOVAL PROCEDURE 1. Remove the front door pull cup from the front door trim panel. Armrest Pull Cup Replacement (Impala). 2. Disconnect the electrical connectors from the front door power window control switch. 3. Remove the front door window control switch from the front door pull cup using a small flat-bladed tool at the side of the power window control switch in order to release the front door power window control switch retainer. INSTALLATION PROCEDURE 1. Install the front door power window control switch to the front door pull cup pressing into place until fully seated. 2. Connect the electrical connectors to the front door power window control switch. 3. Install the front door pull cup to the front door trim panel. Armrest Pull Cup Replacement (Impala). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement > Page 14214 Power Window Switch: Service and Repair Rear Door Power Window Switch Replacement REMOVAL PROCEDURE 1. Remove the rear door pull cup from the rear door trim panel. 2. Disconnect the electrical connectors from the power window control switch. 3. Remove the rear door window control switch from the front door pull cup using a small flat-bladed tool at the side of the power window control switch in order to release the power window control switch retainer. 4. Remove the power window control switch from the rear door pull cup. INSTALLATION PROCEDURE 1. Install the rear door power window control switch to the rear door pull cup pressing into place until fully seated. 2. Connect the electrical connectors to the rear door power window control switch. 3. Install the rear door pull cup to the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service and Repair > Window Channel Retainer Replacement - Front Door Window Frame: Service and Repair Window Channel Retainer Replacement - Front Door REMOVAL PROCEDURE 1. Remove the outside rearview mirror. 2. Pull down the front door window channel in order to gain access to the rivets. 3. Loosen the front door frame applique screws. 4. Drill out the rivets. 5. Remove the front door window channel retainer from the front door. INSTALLATION PROCEDURE 1. Position the front door window channel retainer to the front door. 2. Install the window channel retainer rivets. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the front door frame applique screws. 4. Install the front door window channel in position. 5. Install the outside mirror. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service and Repair > Window Channel Retainer Replacement - Front Door > Page 14219 Window Frame: Service and Repair Window Channel Retainer Replacement - Rear Door REMOVAL PROCEDURE 1. Partially remove the upper portion of the rear door frame appliques. 2. Pull downwards on the rear door window channel to gain access to the rivets. 3. Drill out the rivets. 4. Remove the forward screw to the rear window channel retainer. 5. Remove the rear window channel retainer from the rear door. INSTALLATION PROCEDURE 1. Position the rear window weatherstrip retainer. 2. Push downwards on the rear door window channel to gain access to the rivets holes. 3. Install weather strip retainer rivets. 4. Install the rear door frame applique. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Back Window Glass Moulding / Trim > Component Information > Service and Repair Back Window Glass Moulding / Trim: Service and Repair Rear Window Reveal Molding Replacement Removal Procedure Important: You must remove the rear window in order to replace the rear window reveal molding. The original rear window reveal molding must be replaced with a new service part after removal. 1. Use a flat-bladed tool in order to pry the end of the rear window reveal molding out approximately 75 mm (3 in) from the body. 2. Remove the rear window reveal molding, pulling the rear window reveal molding slowly away from the body. 3. Remove the rear window. Refer to Rear Window Replacement (See: Service and Repair). Installation Procedure Important: The new rear window reveal moldings are primed and will adhere to the urethane adhesive. Use a heat lamp, or heat gun if needed, in order to make the rear window reveal molding more pliable. 1. Wipe the rear window area with a clean, dampened cloth using GM Window Cleaner GM P/N 1050427 or isopropyl alcohol in order to clean the surface of the rear window for the installation of the new rear window reveal molding. Allow to air dry. 2. Install the rear window reveal molding to the rear window, starting from the center , hand press the rear window reveal molding into place. 3. Apply tape if needed, in order to keep the rear window reveal molding on the rear window. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Back Window Glass Moulding / Trim > Component Information > Service and Repair > Page 14225 4. Install the rear window. Refer to Rear Window Replacement (See: Service and Repair). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Corner Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Front Corner Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window Front Door Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Window REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Remove the front door water deflector. 3. Remove the front door outer belt sealing strip. 4. Remove the front door window. 5. Remove the screws from the front door window channel. 6. Remove the front door window channel from the front door frame. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 14235 7. Remove the front door channel from the front door. 8. Remove the screw from the front door rear window channel. 9. Remove the front door rear window channel from the front door slot by pulling down to disengage the retainer clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 14236 10. Remove the front door rear window channel from the front door through the access hole in the inner front door panel. INSTALLATION PROCEDURE 1. Position the front door window channel front channel into the front door. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 14237 2. Install the front door window channel screws. Tighten Tighten the front door window channel screws to 10 N.m (89 lb in). 3. Install the front door window channel to the front door starting in the top corner working out in both directions. Firmly seat the front door window channel to the front door. 4. Install the front door rear window channel to the front door through the access hole in the inner front door panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 14238 5. Install the front door rear window channel to the front door slot by pushing up to engage the retainer clip. 6. Install the screw to the front door rear window channel. Tighten Tighten the front door weatherstrip channel screws to 10 N.m (89 lb in). 7. Install the front door window. 8. Inspect the front door window for proper operation. 9. Install the front door outer belt sealing strip. 10. Install the front door water deflector. 11. Install the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 14239 Front Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Front Side Door Window Weatherstrip Replacement (Impala) Removal Procedure 1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (Impala) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 2. Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement (Impala) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 3. Remove the front door outer belt sealing strip. Refer to Front Side Door Window Belt Outer Sealing Strip Replacement (Impala) (See: Door Window Sealing Strip). 4. Remove the front door window. Refer to Front Side Door Window Replacement (Impala) (See: Service and Repair/Front Side Door Window Replacement). 5. Remove the screws from the front door window channel. 6. Remove the front door window channel from the front door frame. 7. Remove the front door window channel from the front door. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 14240 8. Remove the screw from the front door rear window channel. 9. Remove the front door rear window channel from the front door slot by pulling down to disengage the retainer clip. 10. Remove the front door rear window channel from the front door through the access hole in the inner front door panel. Installation Procedure 1. Position the front door window channel front channel into the front door. Notice: Refer to Fastener Notice in Cautions and Notices. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 14241 2. Install the front door window channel screws. Tighten the front door window channel screws to 10 Nm (89 lb in). 3. Install the front door window channel to the front door starting in the top corner working out in both directions. Firmly seat the front door window channel to the front door. 4. Install the front door rear window channel to the front door through the access hole in the inner front door panel. 5. Install the front door rear window channel to the front door slot by pushing up to engage the retainer clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 14242 6. Install the screw to the front door rear window channel. Tighten the front door weatherstrip channel screws to 10 Nm (89 lb in). 7. Install the front door window. Refer to Front Side Door Window Replacement (Impala) (See: Service and Repair/Front Side Door Window Replacement). 8. Inspect the front door window for proper operation. 9. Install the front door outer belt sealing strip. Refer to Front Side Door Window Belt Outer Sealing Strip Replacement (Impala) (See: Door Window Sealing Strip). 10. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement (Impala) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 11. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (Impala) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 14243 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Front Side Door Window Belt Outer Sealing Strip Replacement (Impala) Removal Procedure 1. Remove the outside rearview mirror. Refer to Power Mirror Replacement (Impala) (See: Body and Frame/Mirrors/Service and Repair/Power Mirror Replacement). 2. Remove the rear screw from the front door outer belt sealing strip. 3. Remove the front door outer belt sealing strip. Installation Procedure 1. Position the front door outer belt sealing strip to the front door pinch-weld flange. 2. Install the front door outer belt sealing strip to the front door pinch-weld flange pressing into place until fully seated. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screw to the rear of the front door outer belt sealing strip. Tighten the outer belt sealing strip screw to 2 Nm (18 lb in). 4. Install the outside rearview mirror. Refer to Power Mirror Replacement (Impala) (See: Body and Frame/Mirrors/Service and Repair/Power Mirror Replacement). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Quarter Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Technical Service Bulletins > Page 14248 Quarter Window Glass: Service and Repair Quarter Window Replacement (Impala) Tools Required * J 39032 Stationary Glass Removal Tool * Urethane Adhesive Kit GM P/N 12346392 or Equivalent * Isopropyl Alcohol or Equivalent * Cartridge-type Caulking Gun * Commercial-type Utility Knife * Razor Blade Scraper * Suction Cups * Plastic Paddle Removal Procedure Important: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and inner trim of the window. 1. Remove the upper quarter trim. Refer to Quarter Upper Trim Panel Replacement (Impala) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Upper Trim Panel Replacement) in Interior Trim. 2. Remove the lower quarter trim. Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Lower Rear Trim Panel Replacement)Q in Interior Trim. Caution: When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and gloves in order to reduce the chance of personal injury. Important: Keep the cutting edge of the tool against the stationary window. This will allow the urethane adhesive to be separated from the stationary window. Leave a base of urethane on the pinchweld flange. The only suitable lubrication is clear water. 3. J 39032 in order to remove the stationary window. Do this from inside the vehicle to protect the outer surface of the paint. 4. Remove the quarter modular window from the pinchweld flange. Installation Procedure 1. Verify all primers and urethane adhesive are within expiration dates. Caution: When replacing stationary windows, use Urethane Adhesive Kit GM P/N 12346392 (Canadian P/N 10952983), or a urethane adhesive system meeting GM Specification GM3651G, to maintain original installation integrity. Failure to use the urethane adhesive kit will result in poor retention of the window which may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury. 2. Inspect for any of the following problems in order to help prevent future breakage of the stationary window: * The flange of the window opening * The stationary window reveal molding * High weld * Solder spots * Hardened spot weld sealer * Any other obstruction or irregularity in the pinchweld flange. Important: If corrosion of the pinchweld flange is present, or if sheet metal repairs or replacements are required, the pinchweld flange Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Technical Service Bulletins > Page 14249 must be refinished in order to restore the bonding area strength. If paint repairs are required, mask the flange bonding area prior to applying the color coat in order to provide a clean primer only surface. Materials such as BASF DE17(R), DuPont 2610(R), Sherwin-Williams PSE 4600 and NP70 (R) and Martin-Semour 5120 and 5130 (R) products are approved for this application. 3. After repairing the open as indicated, perform the following steps: 4. Inspect the condition of the stationary window opening and the adhesives bead to determine which installation method should be used. Refer to Short Method Description (See: Description and Operation/Short Method Description) short method or Extended Method Description (See: Description and Operation/Extended Method Description) extended method for guidelines. 5. Remove no more of the urethane adhesive than necessary in order to maintain the original shape. This will ensure the proper clearance between the stationary window and the pinchweld flange. 6. After repairing the opening as indicated, shake the pinchweld primer (black #3) for at least one minute. Caution: Failure to prep the area prior to the application of primer may cause insufficient bonding of urethane adhesive. Insufficient bonding of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury. 7. Use a new dauber to apply the pinchweld primed (black #3) to the surface of the bonding area. 8. Allow the primer to dry for approximately 10 minutes, Ensure that all nicks and scratches are covered. 9. With the aid of an assistant install the stationary window into the opening. 10. Use masking tape in order to mark the location of the stationary window in the opening. 11. Slit the masking tape at the top edge of the stationary window. 12. With the aid of an assistant remove the stationary window from the opening. 13. Place the stationary window inside up on a clean, protected surface. Important: Do not remove all traces of the adhesive. Remove all mounds or loose pieces of urethane adhesive. 14. If the extended method is being used remove all but approximately 2 mm (3/64 in) of the existing bead of adhesive from the pinchweld flange. 15. Clean around the edge of the inside surface of the stationary window with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth. Important: Do not apply the (black #3) primer to the existing bead of the urethane adhesive. Apply the primer only to nicks, scratches or the primed surfaces. 16. Shake the pinchweld primer (black #3) for at least one minute. 17. Use a new dauber to apply the primer to the surface of the pinchweld flange. 18. Allow the glass primer to dry for approximately 10 minutes. Important: Use care when applying the prep (clear #1) to stationary window. This primer dries almost instantly and may stain the viewing area of the stationary window if not applied evenly. 19. If installing a new encapsulated stationary window, use a new dauber, in order to apply the stationary window prep (clear #2) to the area approximately 10 mm to 16 mm (3/8 in to 5/8 in) around the entire perimeter of the glass inner surface of the primer/bonding areas). The primer is good up to 8 hours after applying it to the glass. The primed surface of the glass must be kept clean. 20. Allow the glass primer to dry for approximately 10 minutes. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Technical Service Bulletins > Page 14250 21. If using the short method, cut the tip of the applicator nozzle in order to provide a bead of 6.0 mm (1/4 in). 22. If using the extended method, cut the applicator nozzle in order to provide a bead 10.5 mm (0.14 in) wide and 10.5 mm (0.14 in) high. 23. Use a cartridge type caulking gun to apply a smooth, continuous bead of new urethane adhesive. 24. When using the short method, apply the urethane adhesive to the existing bead of urethane adhesive on the body. 25. When using the extended method, use the edge of the stationary window or the inside edge of the reveal molding as a guide for the nozzle in order to apply the urethane adhesive (1) to the inner surface of the stationary window (3). 26. With the aid of an assistant, use the suction cups in order to install the stationary window into the opening. 27. Align the tape on the stationary window and the body. 28. Press the stationary window firmly into place. 29. Tape the stationary window to the body in order to minimize movement until the urethane adhesive cures. 30. Clean any excess urethane adhesive from the body. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Technical Service Bulletins > Page 14251 Important: Do not direct a hard stream of high pressure water to the freshly applied urethane adhesive. 31. Use a soft spray of warm water in order to immediately water test the rear window. Inspect the stationary window for leaks. 32. Use a soft spray in order to water test the stationary window immediately. 33. If any leaks are found, use a plastic paddle in order to apply extra urethane at the leak point. 34. Retest stationary window for leaks. Caution: Insufficient curing of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury. * For the moisture-curing type of urethane adhesive, allow a minimum of 6 hours at 21°C (70°F) or greater and with at least 30 percent relative humidity. Allow at least 24 hours for the complete curing of the urethane adhesive. * For the chemical-curing type of urethane adhesive, allow a minimum of 1 hour. Do NOT physically disturb the repair area until after these minimum times have elapsed. 35. The following conditions must be maintained to properly cure the urethane. 1. Partially lower a door stationary window in order to prevent pressure buildups when closing doors before the urethane adhesive cures. 2. Do not drive the vehicle until the urethane adhesive is cured. Refer to the above curing times. 3. Do not use compressed air in order to dry the urethane adhesive. 36. Install the lower quarter trim. Refer to Quarter Lower Rear Trim Panel Replacement (Impala) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Lower Rear Trim Panel Replacement) in Interior Trim. 37. Install the upper quarter trim panel. Refer to Quarter Upper Trim Panel Replacement (Impala) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Quarter Upper Trim Panel Replacement) in Interior Trim. 38. Remove the tape from the quarter modular window and the body. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window Rear Door Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door Window REMOVAL PROCEDURE 1. Place the rear window in the full down position. 2. Remove the rear door trim panel. 3. Remove the outer belt sealing strip. 4. Remove the rear window channel from the door. INSTALLATION PROCEDURE 1. Position the rear window channel to the rear door starting in the corner.Work outward in both directions. 2. Firmly seat the rear window channel to the rear door. 3. Inspect the rear door window for proper operation. 4. Install the outer belt sealing strip. 5. Install the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 14257 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Channel Rear Side Door Window Channel Retainer Replacement (Impala) Removal Procedure 1. Partially remove the upper portion of the rear door frame appliques. Refer to Rear Door Frame Applique Replacement (Impala Front) ()Rear Door Frame Applique Replacement (Impala Rear) (). 2. Pull downwards on the rear door window channel to gain access to the rivets. 3. Drill out the rivets. 4. Remove the forward screw to the rear window channel retainer. 5. Remove the rear window channel retainer from the rear door. Installation Procedure 1. Position the rear window weatherstrip retainer. 2. Push downwards on the rear door window channel to gain access to the rivets holes. 3. Install weather strip retainer rivets. 4. Install the rear door frame applique. Refer to Rear Door Frame Applique Replacement (Impala Front) ()Rear Door Frame Applique Replacement (Impala Rear) (). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 14258 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Rear Side Door Window Weatherstrip Replacement (Impala) Removal Procedure 1. Place the rear window in the full down position. 2. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair 3. Remove the outer belt sealing strip. Refer to Rear Side Door Window Outer Sealing Strip Replacement (Impala) (See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Weatherstrip/Service and Repair/Rear Side Door Window Outer Sealing Strip Replacement). 4. Remove the rear window channel from the door. Installation Procedure 1. Position the rear window channel to the rear door starting in the corner. Work outward in both directions. 2. Firmly seat the rear window channel to the rear door. 3. Inspect the rear door window for proper operation. 4. Install the outer belt sealing strip. Refer to Rear Side Door Window Outer Sealing Strip Replacement (Impala) (See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Weatherstrip/Service and Repair/Rear Side Door Window Outer Sealing Strip Replacement). 5. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 14259 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip REMOVAL PROCEDURE 1. Position the rear window all the way down. 2. Remove the rear door trim panel to have access to these screws. 3. Remove the rear door outer belt sealing strip screws. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 14260 4. Remove the rear window outer belt sealing strip by pulling the sealing strip from the rear door pinch-weld flange. INSTALLATION PROCEDURE 1. Position the rear door outer belt sealing strip to the rear door pinch-weld flange. 2. Install the rear door outer belt sealing strip to the pinch-weld flange, pressing into place until full seated. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 14261 NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the rear door outer belt sealing strip screws. Tighten Tighten the rear door outer belt sealing strip screws to 1.5 N.m (13 lb in). 4. Install Rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Replacement (Impala) Removal Procedure 1. Position the front door window with a 6.3 mm (1/4 in) space at the top. 2. Tape the window to the window frame. 3. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (Impala) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 4. Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement (Impala) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 5. Disconnect the front window from the front window regulator carrier plate. Refer to Front Side Door Window Replacement (Impala) (See: Window Glass/Front Door Window Glass/Service and Repair/Front Side Door Window Replacement). 6. Disconnect the electrical connector from the front window regulator motor. 7. Loosen the bolts on the front window regulator motor. 8. Loosen the top bolts and remove the lower bolts on the front window regulator rail. 9. Remove the front window regulator, lifting up and out from the key slots on the front door inner panel and through the rear access hole. Installation Procedure 1. Install the top window regulator bolts half way into the window regulator motor and the rail. 2. Position the front window regulator rail through the rear access hole first. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 14266 3. Position the front window regulator motor through the rear access hole. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the front window regulator bolts into the key slots. Tighten the front window regulator motor and the rail bolts to 10 Nm (89 lb in). 5. Remove the tape from the front window and position the front window to the front window regulator carrier plate. 6. Connect the front window to the front window regulator carrier plate. Refer to Front Side Door Window Replacement (Impala) (See: Window Glass/Front Door Window Glass/Service and Repair/Front Side Door Window Replacement). 7. Connect the electrical connector to the front window regulator motor. 8. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement (Impala) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 9. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (Impala) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Impala) Removal Procedure 1. Position the front door window with a 6.3 mm (1/4 in) space at the top. 2. Tape the window to the window frame. 3. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair. 4. Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (Impala) (See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair). 5. Disconnect the rear window from the rear window regulator carrier plate. Refer to Rear Side Door Window Replacement (Impala) (See: Window Glass/Rear Door Window Glass/Service and Repair). 6. Disconnect the electrical connector from the rear window regulator motor. 7. Loosen the bolts on the rear window regulator motor. 8. Loosen the bolts on the rear window regulator rail. 9. Remove the rear window regulator, lifting up and out from the key slots on the rear door inner panel and through the rear access hole. Installation Procedure 1. Install the rear window regulator bolts half way into the rear window regulator motor and the rail. 2. Position the rear window regulator rail through the rear access hole first. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 14270 3. Position the rear window regulator motor through the rear access hole. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the rear window regulator into the key slots. Tighten the rear window regulator motor and the rail bolts to 10 Nm (89 lb in). 5. Remove the tape from the rear window and position the rear window to the rear window regulator carrier plate. 6. Connect the rear window to the rear window regulator carrier plate. Refer to Rear Side Door Window Replacement (Impala) (See: Window Glass/Rear Door Window Glass/Service and Repair). 7. Connect the electrical connector to the rear window regulator motor. 8. Install the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (Impala) (See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair). 9. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair Windshield Moulding / Trim: Service and Repair Windshield Reveal Molding Replacement Removal Procedure Important: * Be sure to prefit the windshield reveal molding to the windshield then as an assembly on the body prior to actual installation. * When replacing the windshield, the original windshield reveal molding cannot be reused and must be replaced with a new molding. * The new windshield reveal moldings are primed and will adhere to the urethane adhesive. * A heat lamp may be used to make the windshield reveal molding more pliable. * The windshield reveal molding cannot be replaced without removing the windshield. 1. Remove the windshield using a flat-bladed tool, and carefully pry the end of the windshield reveal molding out about 75 mm (3 in). 2. Grasp the windshield reveal molding by hand and slowly pull the windshield reveal molding away from the body. 3. Remove the windshield. Refer to Windshield Replacement (See: Service and Repair). Installation Procedure 1. Start from center and hand press the windshield reveal molding into place. Tape can be applied to keep windshield reveal molding flush with windshield. 2. Prefit the windshield reveal molding and the windshield then as an assembly on the body prior to actual installation. 3. Install the windshield. Refer to Windshield Replacement (See: Service and Repair). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Component Locations Wiper Control Module: Component Locations Locations View LR of the engine compartment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Component Locations > Page 14281 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions Wiper Control Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14284 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14285 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14286 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14287 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14288 Wiper Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14289 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14290 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14291 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14292 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14293 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14294 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14295 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14296 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14297 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14298 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14299 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14300 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14301 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14302 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14303 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14304 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14305 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14306 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14307 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14308 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14309 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14310 Windshield Wiper System Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14311 Wiper/Washer System (Pulse) Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Turn Signal Switch, Headlamp Dimmer Switch, Wiper/Washer Switch Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Turn Signal Switch, Headlamp Dimmer Switch, Wiper/Washer Switch > Page 14320 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Turn Signal Switch, Headlamp Dimmer Switch, Wiper/Washer Switch > Page 14321 Windshield Washer Switch: Locations Windshield Wiper/Washer Switch On the multifunction switch. On the RH side of the steering column. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Turn Signal Switch, Headlamp Dimmer Switch, Wiper/Washer Switch > Page 14322 Windshield Washer Switch: Locations Windshield Washer Solvent Level Switch LF of the inner fender well, In the washer reservoir. RF of the inner fender well, In the washer reservoir. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14325 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14326 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14327 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14328 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14329 Windshield Washer Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14330 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14331 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14332 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14333 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14334 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14335 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14336 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14337 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14338 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14339 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14340 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14341 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14342 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14343 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14344 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14345 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14346 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14347 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14348 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14349 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14350 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14351 Windshield Washer Solvent Level Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14352 Wiper/Washer System (Pulse) Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Windshield Wiper Switch Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Windshield Wiper Switch > Page 14357 Wiper Switch: Locations Windshield Wiper/Washer Switch On the multifunction switch. On the RH side of the steering column. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Windshield Wiper Switch > Page 14358 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions Wiper Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14361 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14362 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14363 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14364 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14365 Wiper Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14366 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14367 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14368 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14369 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14370 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14371 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14372 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14373 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14374 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14375 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14376 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14377 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14378 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14379 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14380 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14381 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14382 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14383 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14384 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14385 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14386 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14387 Wiper/Washer System (Pulse) Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations Windshield Washer Pump: Locations Locations View LF of inner fender well, in the washer reservoir. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Pump: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14396 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14397 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14398 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14399 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14400 Windshield Washer Pump: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14401 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14402 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14403 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14404 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14405 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14406 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14407 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14408 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14409 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14410 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14411 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14412 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14413 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14414 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14415 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14416 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14417 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14418 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14419 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14420 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14421 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14422 Windshield Washer Pump Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 14423 Wiper/Washer System (Pulse) Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Page 14424 Windshield Washer Pump: Service and Repair REMOVAL PROCEDURE 1. Remove the front fender liner. 2. Disconnect the electrical connector and the hose from the washer pump. 3. Remove the washer pump from the washer solvent container. 3.1. Pull the top of the washer pump out from the side of the washer solvent container. 3.2. Pull the washer pump out of the washer solvent container. 4. Remove the washer pump grommet from the washer solvent container. INSTALLATION PROCEDURE 1. Install the washer pump grommet into the washer solvent container. 2. Install the washer pump into the washer solvent container. 2.1. Push the washer pump inlet into the washer solvent container completely. 2.2. Push the top of the washer pump into the side of the washer solvent container. 3. Connect the electrical connector and the hose to the washer pump. 4. Install the front fender liner. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair Windshield Washer Reservoir: Service and Repair REMOVAL PROCEDURE 1. Remove the screw from the tube assembly and the vehicle. 2. Remove the tube with the seal from the washer solvent container. 3. Remove the seal from the tube. 4. Remove the front fender liner. 5. Disconnect the electrical connector and the hose from the washer pump. 6. Remove three screws and the washer solvent container from the vehicle. 7. Disconnect the connector from the washer solvent level sensor. 8. Remove two screws and the bracket from the washer solvent container. 9. Remove the solvent level sensor and seal. 10. Remove the washer pump and grommet. INSTALLATION PROCEDURE 1. Install the washer pump and the grommet. 2. Install the solvent level sensor and seal. 3. Install the bracket with two screws on the washer solvent container. Tighten Tighten the screws to 7 N.m (62 lb in). 4. Connect the electrical connector to the washer solvent level sensor. 5. Install the washer solvent container on the vehicle with three screws. Tighten Tighten the screws to 10 N.m (88 lb in). 6. Connect the electrical connector and the hose to the washer pump. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 14428 7. Install the front fender liner. 8. Install the seal onto the tube. 9. Install the tube with the seal on the washer solvent container. 10. Install the tube on the vehicle with the screw. Tighten Tighten the screw to 10 N.m (88 lb in). Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Turn Signal Switch, Headlamp Dimmer Switch, Wiper/Washer Switch Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Turn Signal Switch, Headlamp Dimmer Switch, Wiper/Washer Switch > Page 14433 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Turn Signal Switch, Headlamp Dimmer Switch, Wiper/Washer Switch > Page 14434 Windshield Washer Switch: Locations Windshield Wiper/Washer Switch On the multifunction switch. On the RH side of the steering column. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Turn Signal Switch, Headlamp Dimmer Switch, Wiper/Washer Switch > Page 14435 Windshield Washer Switch: Locations Windshield Washer Solvent Level Switch LF of the inner fender well, In the washer reservoir. RF of the inner fender well, In the washer reservoir. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14438 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14439 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14440 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14441 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14442 Windshield Washer Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14443 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14444 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14445 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14446 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14447 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14448 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14449 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14450 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14451 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14452 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14453 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14454 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14455 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14456 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14457 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14458 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14459 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14460 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14461 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14462 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14463 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14464 Windshield Washer Solvent Level Switch Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14465 Wiper/Washer System (Pulse) Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications Wiper Arm: Specifications Wiper Arm Nut 30 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm Blade Replacement Wiper Arm: Service and Repair Wiper Arm Blade Replacement REMOVAL PROCEDURE 1. Turn the ignition switch to the ACCY position. 2. Set the wiper switch to the PULSE position. 3. Turn the ignition off when the wipers are in the midwipe position. 4. Push in the button of the wiper blade clip and remove the wiper blade from the inside radius of the wiper arm. 5. Bring the wiper arm out through the opening in the wiper blade. INSTALLATION PROCEDURE 1. Insert the hook of the wiper arm through the opening in the wiper blade. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 14471 2. Position the wiper blade pivot in the inside radius of the wiper arm hook. 3. Pull the wiper blade pivot into the wiper arm hook until the pivot locks into the hook. 4. Operate the wipers and inspect for proper operation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 14472 Wiper Arm: Service and Repair Wiper Arm Replacement REMOVAL PROCEDURE TOOLS REQUIRED J 39822 Wiper Arm Puller 1. Turn the ignition switch to the ACCY position. 2. Set the wiper switch to the PULSE position. 3. Turn the ignition off when wiper arms are at the bottom of the wipe pattern (innerwipe) and not moving. 4. Disconnect the washer hose from the washer nozzle. 5. Remove the cover from the nut. 6. Remove the nut from the wiper arm and the wiper transmission drive shaft. IMPORTANT: A J 39822 Wiper Arm Puller may be used if the wiper arm cannot be removed from wiper transmission drive shaft by rocking. The pin from the new wiper arm may be used to ease removal. 7. Remove the wiper arm from the wiper transmission drive shaft by rocking. 8. Remove the wiper blade from wiper arm. INSTALLATION PROCEDURE 1. Install the wiper blade on the wiper arm. 2. Install the wiper arm on the wiper transmission drive shaft. 2.1. Put the ignition switch in the ACCY position. 2.2. Set the wiper switch to the PULSE position. The windshield wiper system should be operating. 2.3. Turn the ignition off when the wiper drive system is at the bottom of its wipe cycle (innerwipe) and not moving. IMPORTANT: ^ The measuring device must be held at 90 degrees (perpendicular) to the wiper blade. ^ The pin, or a same-size drill bit, should be used in the wiper arm during installation. 2.4. Install the wiper arm on the wiper transmission drive shaft while maintaining the following distances: ^ RH 97-107 mm (3.82-4.21 in) from the end of the wiper arm to the air inlet screen. ^ LH 125-147 mm (4.92-5.78 in) from the wiper blade tip to the air inlet grille panel. 3. Install the nut onto the wiper transmission drive shaft and the wiper arm. Tighten Tighten the nut to 27 N.m (20 lb ft). 4. Remove the pin from wiper arm. 5. Install the cover on the nut. IMPORTANT: Lubricate the washer hose with the windshield washer solvent to ease the installation on the washer nozzle. 6. Connect the washer hose onto the washer nozzle. 7. Operate the wipers and check for proper operation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance Wiper Blade: Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance > Page 14477 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 14478 Wiper Blade: Service and Repair REMOVAL PROCEDURE IMPORTANT: Replace the wiper blade element if it is removed from the wiper blade. 1. Remove the wiper blade from the wiper arm. Refer to Wiper Arm Blade Replacement 2. Remove the bottom claws (2) of the wiper blade (1) from the notches in the wiper blade element (3). 3. Pull the wiper blade element (3) out through the wiper blade claws (2). INSTALLATION PROCEDURE IMPORTANT: keep the wiper blade claws in the rubber claw channel of the wiper blade element. Do not allow the claws of the wiper blade to contact the metal spline of the wiper blade element. 1. Insert the open end of the wiper blade element (3) into the bottom claws of the wiper blade (2). 2. Guide the wiper blade element (3) through the wiper blade (1) claw sets. 3. Engage the bottom claw (2) of the wiper blade (1) into the notches in wiper blade element (3). 4. Install the wiper blade onto the wiper arm. Refer to Wiper Arm Blade Replacement. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Component Locations Wiper Control Module: Component Locations Locations View LR of the engine compartment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Component Locations > Page 14483 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions Wiper Control Module: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14486 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14487 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14488 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14489 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14490 Wiper Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14491 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14492 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14493 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14494 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14495 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14496 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14497 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14498 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14499 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14500 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14501 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14502 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14503 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14504 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14505 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14506 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14507 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14508 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14509 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14510 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14511 Equivalents - Decimal And Metric (Part 2 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14512 Windshield Wiper System Module Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14513 Wiper/Washer System (Pulse) Schematics Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications Wiper Motor: Specifications Wiper Motor Cover Screws 2 Nm Wiper Motor Crank Arm Screws 16 Nm Wiper Motor Screws 7 Nm Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 14517 Wiper Motor: Locations LF of the dash, under cowl cover. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Cover Replacement Wiper Motor: Service and Repair Wiper Motor Cover Replacement REMOVAL PROCEDURE TOOLS REQUIRED J 39232 Wiper Transmission Separater 1. Remove the wiper arms from the vehicle. 2. Remove the air inlet grille panel from the vehicle. 3. Remove the connector from the wiper motor. 4. Remove the wiper transmission from wiper motor crank arm using the J 39232. 5. Remove three screws and the wiper drive system module from the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Cover Replacement > Page 14520 6. Remove three screws and the wiper motor cover from the wiper motor. INSTALLATION PROCEDURE TOOLS REQUIRED J 39529 Wiper Transmission Installer 1. Install the wiper motor cover on the wiper motor with three screws. Tighten Tighten screws to 2 N.m (18 lb in). 2. Install the wiper drive system module on the vehicle with three screws. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Cover Replacement > Page 14521 Tighten Tighten screws to 10 N.m (88 lb in). 3. Install the wiper transmission on the wiper motor crank arm using the J 39529. 4. Install the connector to the wiper motor. 5. Install the air inlet grille panel on the vehicle. 6. Install the wiper arms on the vehicle. 7. Operate the wipers and check for proper operation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Cover Replacement > Page 14522 Wiper Motor: Service and Repair Wiper Motor Replacement REMOVAL PROCEDURE TOOLS REQUIRED J 39232 Wiper Transmission Separator 1. Remove the wiper arms. 2. Remove the air inlet grille panel from the vehicle. 3. Remove the connector from the wiper motor. 4. Remove the wiper transmission from the wiper motor crank arm using the J 39232. 5. Remove three screws and the wiper drive system module from the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Cover Replacement > Page 14523 6. Remove the wiper motor crank arm from the wiper motor. 6.1. Remove the rubber boot from the wiper motor crank arm. 6.2. Loosen the screw. 6.3. Tap on the screw with a soft-faced mallet while holding up on the wiper motor crank arm until the wiper motor crank arm is loose on wiper motor. 6.4. Remove the screw and wiper motor crank arm from wiper motor. 7. Remove three screws and wiper motor from wiper drive system module. 8. Remove the shaft seal and the water shield from the wiper motor. INSTALLATION PROCEDURE TOOLS REQUIRED J 39529 Wiper Transmission Installer Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Cover Replacement > Page 14524 1. Install the water shield and shaft seal on the wiper motor. 2. Install the wiper motor on the wiper drive system module with three screws. Tightening Tighten three screws to 7 N.m (62 lb in). 3. Install the wiper motor crank arm on the wiper motor. 3.1. Install the connector to the wiper motor. 3.2. Turn the ignition switch to the ACCY position. 3.3. Set the wiper switch to the PULSE position. The wiper motor should be operating. 3.4. Turn the ignition off when the wiper motor is in the innerwipe position and not moving. 3.5. Disconnect the connector from the wiper motor. 3.6. Install the wiper motor crank arm on the wiper motor while maintaining a 4-8 mm (0.157-0.314 in) gap between wiper motor crank arm and bracket tab. 3.7. Install the screw. 3.8. Inspect the gap between wiper motor crank arm and bracket tab. If the gap is not 4-8 mm (0.157-0.314 in), remove the crank arm and repeat installation. Tighten Tighten the screw to 16 N.m (142 lb in). 3.9. Install the rubber boot onto the wiper motor crank arm. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Cover Replacement > Page 14525 4. Install the wiper drive system module on the vehicle with three screws. Tighten Tighten the screws to 10 N.m (88 lb in). 5. Install the wiper transmission on the wiper motor crank arm using the J39529. 6. Install the connector onto the wiper motor. 7. Install the air inlet grille panel on the vehicle. 8. Install the wiper arms. 9. Operate the wipers and inspect for proper operation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Cover Replacement > Page 14526 Wiper Motor: Service and Repair Wiper Motor Crank Arm Replacement REMOVAL PROCEDURE TOOLS REQUIRED J 39232 Wiper Transmission Separator 1. Remove the wiper arms. 2. Remove the air inlet grille panel from the vehicle. 3. Remove the wiper transmission from the wiper motor crank arm using the J 39232. 4. Remove three screws and the wiper drive system module from the vehicle. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Cover Replacement > Page 14527 5. Remove the wiper motor crank arm from the wiper motor. 5.1. Remove the rubber boot from the wiper motor crank arm. 5.2. Loosen the screw. 5.3. Tap on the screw with a soft-faced mallet while holding up on the wiper motor crank arm until the wiper motor crank arm is loose on wiper motor. 5.4. Remove the screw and wiper motor crank arm from wiper motor. INSTALLATION PROCEDURE TOOLS REQUIRED J 39529 Wiper Transmission Installer 1. Install the wiper motor crank arm on the wiper motor. 1.1. Install the connector to the wiper motor. 1.2. Turn the ignition switch to the ACCY position. 1.3. Set the wiper switch to the PULSE position. The wiper motor should be operating. 1.4. Turn the ignition off when the wiper motor is in the innerwipe position and not moving. 1.5. Disconnect the connector from the wiper motor. 1.6. Install the wiper motor crank arm on the wiper motor while maintaining a 4-8 mm (0.157-0.314 in) gap between wiper motor crank arm and bracket tab. 1.7. Install the screw. 1.8. Inspect the gap between wiper motor crank arm and bracket tab. If the gap is not 4-8 mm (0.157-0.314 in), remove the crank arm and repeat installation. Tighten Tighten the screw to 16 N.m (142 lb in). 1.9. Install the rubber boot onto the wiper motor crank arm. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Cover Replacement > Page 14528 2. Install the wiper drive system module on the vehicle with three screws. Tighten Tighten the screws to 10 N.m (88 lb in). 3. Install the wiper transmission on the wiper motor crank arm using the J 39529. 4. Install the connector onto the wiper motor. 5. Install the air inlet grille panel on the vehicle. 6. Install the wiper arms. 7. Operate the wipers and inspect for proper operation. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Windshield Wiper Switch Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Windshield Wiper Switch > Page 14533 Wiper Switch: Locations Windshield Wiper/Washer Switch On the multifunction switch. On the RH side of the steering column. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Windshield Wiper Switch > Page 14534 Locations View Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions Wiper Switch: Diagram Information and Instructions Passenger Car Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14537 Electrical Symbols (Part 1 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14538 Electrical Symbols (Part 2 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14539 Electrical Symbols (Part 3 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14540 Electrical Symbols (Part 4 Of 4) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14541 Wiper Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Refer to Strategy Based Diagnosis in General Information in order to properly diagnose and repair the customer concern. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Service Precautions Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery. ^ Antenna location. ^ Transceiver wiring located too close to vehicle electronic modules or wiring. ^ Poor shielding or poor connectors on antenna feed line. ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or two. Fuses Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14542 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Fusible Link Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Connector Position Assurance (CPA) The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone won't meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14543 Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 Heat Gun. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to 0°F from one end and 160°F from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Intermittents Most intermittent are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation. ^ Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specific procedure. ^ Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair Kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14544 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between two points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the two points. Salt Water Spray Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14545 Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 12 ounces of water with approximately 1 tablespoon of salt will yield a salt solution of 5%. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store two snapshots. The ability to record two snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be one of two types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice (Does not contain DTC information) When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For A Short to Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing For Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Intermittent and Poor Connections Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14546 watching the test equipment. ^ Testing for Short to Ground ^ Testing for Continuity ^ Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B Terminal Repair kit or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter Kit on the flat wire harness connector in order to test the circuit in question. Testing For Short To Ground NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14547 The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power teed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14548 Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Fused Jumper Wires IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Heated Oxygen Sensor (HO2S) Wiring Repairs NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. Repairing A Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approx. 9 inches) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14549 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit. If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, it needed, in order to maintain SIR/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in Diagrams in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14550 ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14551 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38215-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38215-B Terminal Repair Kit in order to determine the proper clip size crimp tool and anvil. 6. Overlap the two stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14552 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14553 12. Tape the splice Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Crimp And Seal Splice Table Crimp and Seal Splice Table TOOLS REQUIRED J 38125-B Terminal Repair Kit 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14554 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125 crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14555 Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14556 Wire Size Conversion Table Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14557 5. Re-form the locking device it you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Terminal Position Assurance (TPA) The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. ^ Separate the connector halves (1). ^ Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). ^ Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14558 ^ Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). ^ Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. ^ Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. ^ Reform the lock tang (2) and reset terminal in connector body. ^ Close secondary locks and join connector halves. ^ Verify that circuit is complete and working satisfactorily. ^ Perform system check. Repairing Connector Terminals Use the following repair procedures in order to repair the following: ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B Terminal Repair Kit contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Arrows and Symbols Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14559 This service manual uses various symbols in order to describe different service operations. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14560 Conversion - English/Metric Diagnostic Work Sheets The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. GM Service Bulletin 58-01-01 has information on how to order this diagnostic worksheet. Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14561 Equivalents - Decimal And Metric (Part 1 Of 2) Chevrolet Impala Workshop Manual (V6-3.4L VIN E (2000)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14562 Equivalents - Decimal And Metric (Part 2 Of 2)